Filling MonoblockRef: M165
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Used Hot Filling Triblock F&P Machinery Unica HF glass/PET 24/8/24/6 12000 bph
24 Rinser 8/24 Filler 6 Capper
Model Unica HF PET 24/8/24/6
6.000 BPH 1.0 l or 12.000 BPH 0,25 l.
MAXIMUM Bottle Diameter 105 mm per PET
MINIMUM Bottle Diameter 50 mm
The structure of the turret is a “self-standing” type, with adjustable feet. With a combination plate drilled appropriately so that it would connect exactly with the monoblock conveying organs, the turret is connected to the monoblock basement.
The motorization of the rinsing turret is effected by means of a “large diameter” geared bearing, controlled by a geared pinion realized in plastic material. The pinion is motorized by a speed reducer, which receives the motion from the filler (normally by means of a cardan shaft).
The Used Hot Filling Triblock is fixed without a height adjustment device of the gripper-holder carrousel for neck handling operation.
The bottle-holder gripper is the type with double gripping-hand opening and which guarantees an extremely firm seizing of the bottle, even if it is very heavy. Thanks to the particular shape of the gripper, it has been possible to obtain a considerable improvement relative to the maximum diameters effectable in reference to the machine pitch. The rotation movement and bottle overturning is in fact effected in correspondence to the axis which coincides with the primitive diameter. The bottle gripper pads are an extra-rapid assemble and disassemble type.
The spraying start control and its duration (injection time), is effected by means of a proper rotating manifold with pre-determined phasing. The rinsing treatment is done with or without the bottle presence.
Annular tank to collect the rinsing fluid. It allows the streaming and collection of the water in one point, on the side of the external structure.
Solenoid valve(s) to control the rinsing fluid(s). The valve(s) stops the treatment fluid(s) flow every time the Used Hot Filling Triblock stops and starts it at the machine re-starting.
Pressure regulator(s) for the treatment fluid(s).
Pressure switch(es) for the treatment fluid(s).
Piston Filling turret – The machine consists of:
- Liquid collection side drain with one only discharge point
- All parts in contact with product in mirror polished AISI 316 stainless steel
- Container in feed slat chain conveyor with timing worm screw and non-toxic, anti-wear PVC container introduction star
- AISI 304 stainless steel cylinders and pistons with Teflon sliding pad and special gaskets in sanitary material (FDA approved)
- Valves and plugs made of special material (FDA approved)
- Stainless steel product hopper
- Electro pneumatic no-bottle/no-fill device
NOTE: Orange syrup with sacs will be fed by customer at right temperature
Filling turret hot fill execution – used filling equipment
In particular, Unica HF is designed for filling flat/still products — including Hot Fill — with fibres with a maximum diameter of 1,0 mm and a maximum length of 4 mm.
Filler and filling valves were designed specifically to handle PET bottles with a neck handling transfer system for noncarbonated products.
Filling valves. Innovative filling valves which main feature consists in the TOTAL separate air return allowing high filling hygiene and considerably reducing any possible contamination problem.
Valves are AISI 316 st. steel manufactured, relevant finishing are especially accurate and this give high valve hygiene. The construction shape allows intervention practicality even in the smallest details studied on purpose to make the maintenance as much rapid as possible. The valve has infact the salient characteristic to receive the maintenance without needing to be removed from the filler. The valve presents a pneumatic opening/closing system, which cancel mechanical (wear and reliability) problems; furthermore it allows having one single gasket (sanitary membrane) in contact with the external environment and does not have any motion external/internal internal/external which could risk to provoke product contamination.
Special care was dedicated to the gaskets design, both in the shape and material whose purpose is to give the maximum duration. All gaskets are “alimentary” certificated (F.D.A.) and can bear the sterilization. During the sanitization phase, the sanitizing solution, under dummy bottles presence, enter into contact with each point of the valve. Through the air return slip ring, which during the sanitization works as a sanitizing solution return system, this latter can be then recovered.
The sanitization is controlled by an operator panel and the machine is arranged for this procedure thanks to an electro-pneumatic system which controls all the involved valves.
How it works
Main Product Ring Bowl made of Aisi 316 Stainless steel. All parts inside the filler are mirror polished in Aisi 316 st. steel and connected without any interstice. The whole to guarantee an efficient cleaning operation and machine drainage.
The tank is fed from the bottom by a large Ø central piping which purpose is to ensure the product transfer with no turbulences.
The level is maintained constant thanks to a binomial between the (electronic) capacity probe and the modulating valve at inlet.
The tank is not height adjustable.
Upper rotary slip ring and feeding. In his upper side, the group is characterised by a modular structure composed by independent chambers, while in the bottom side is placed the piping of product adduction. The special and extremely innovative slip ring constructive shape enable the gasket long duration even in absence of lubrication.
Product Feeding And Recycle:
By recirculating the product directly by the filling valves, the product feeding and recycling system ensures the right filling temperature. The system is mounted on the machine board.
Through an over-dimensioned piping, the product is fed through low level, and feeding is controlled by a modulating valve controlled by top-level tank gauges, electronic capacity probes inside the tank, and PT100 sensors on the recycle circuit (to detect the temperature at inlet and outlet).
The main characteristic is the capacity to control the recicled product quantity (needed to guarantee a substantial filling temperature of approx ±1°C), allowing to optimize both during standard working phases and in transition phases (beginning and work-end or during plan stops), guaranting in any case a minimum recycle product content.
The extreme versatility of the recycle is due to the opening of the recycle circuit on the valves, by means of cams which operate on a special push-button (one for each filling valve).
The number, cams extension and possibility of making them working automatically and independently one from the other, thank to “recipes” memorized in PLC, allow to obtain optimal results in terms of recycling minimization and optimization of transition phases.
The product reaches the valve (external) through pipes in communication with the central tank, thus slowing their speed down and removing all turbulences and subsequently all possibilities of stress of product.
Quick insertion of filling valve vent tubes, are quickly replaceable. They are engineered in a simple design that makes reasonable in cost.
The filling system is “by level” and in standard structure allows to have a minimum fill point (not less than 22 mm from the bottle mouth.
PET Bottles: neck handling transferring system. The bottle motion is made through a system applied to the filling valve which allows the bottle lifting in axis with the same, avoiding any possible instability of the bottle. This solution enable us to eliminate the lifting jacks so removing any maintenance unit.
The cam controlled pneumatic lifting system has the characteristic to be enable the possible maintenance operation without any machine stop
Neck handling equipment. This solution allows to continue the neck handling transfer which already occurs on the air conveyors for the whole way inside the machine. Its advantages are expressed by the extremely short change over time as the equipment is a unique one for all formats. Furthermore the machine height adjustment basing on the bottles is not needed anymore, with the single exception of the outlet conveyor.
Basement Completely clad on SS AISI 304, with 20mm-thick Aisi 304 st. steel structure and surface. It is provided with adjustable ground supports and doors for inside inspection and maintenance.
Drive unit group composed by an opportunely dimensioned electrical motor, controlled by an electronic frequency converter (frequency variators). The production speed is adjustable through the Touch Screen assembled on the operator panel. Inside the frame are lodged all mechanical units making both the machine rotation and the bottle motion.
Gears are made of st. steel and loaded nylon, they are all coupled amongst themselves just to obtain the maximum silence and the utmost wear reduction.
Carousel group composed by the supporting structure of ring bowl and valves. It is provided with a central gear (wide diameter ball-bearing fifth wheel) connected to the machine drive unit to ensure the maximum stability and utmost movement precision.
Conveyor of the Used Hot Filling Triblock
Conveyor belts. At the inlet, the machine can be connected to a pneumatic belt conveyor for neck-fed bottles. This air conveyor drops the bottles to a special inlet star which, in its turn, hangs them from the neck too. Bottle out feed belt conveyor with adjustable height running surface.
Perimetral accident prevention guards mainly st. steel realised and positioned on the machine perimeter; they are opportunely projected to be integrated in the basement both on the front side and on the back one. The door opening is controlled by special safety micro and will be possible only when the machine is stopped. The whole is projected, manufactured and tested in accordance with the European Cee regulation 89/37
Pneumatic installation composed by all the control units which control the pneumatic circuit of the machine such as: filters, cylinders, pressure gauges, manometers, electro-valves, valves etc.
Electric Control of the Used Hot Filling Triblock
Electric control board in compliance with the European rules nr. 89/37 CE and separate and independent for each single model. It is normally installed as shown on the installation layout and agreed with the purchaser. The technical characteristics of this unit are listed hereafter:
Aisi 304 st. steel construction;
IP55 waterproof protection;
entirely composed by remote control switches, fuses, PLC and frequency variators;
furthermore it hosts the wiring of the photocell system controlling : bottle presence, emergency stops and speed etc.
Control external operator panel in compliance with the European Ce regulation 89/37 and installed on board the machine. The technical characteristics of this unit are the following ones.
Aisi 304 st. steel construction; control of all functions and of machine diagnostic through the visualisation of all info on the special touch screen (e.g.: start-up; stop; machine stop in case of doors opening, bottle jamming; etc).
The maintenance operations and all adjustments are executed through a portable push button panel.
Manual Lubrication by greasers and oil mists. In order to facilitate access, the greasers are mounted on an external plate of the machine frame.
Electric Power Panel is in compliance with EU directive 89/37 and assembled according to the customer’s plant layout. This unit has the technical features such as construction in AISI 304 stainless steel and IP55 watertight protection. It is complete with switches for the remote control, fuses, PLC and inverter. In addition, it includes the wiring of line control photo-electric system for bottles at the infeed and discharge.
External Operator Control Panel is in compliance with EU directive 89/37. Made of AISI 304 stainless steel, it manages the machine functions (such as start, stop, and emergency mode), as well as diagnostics. The filler’s slow rotation is controlled by a portable jog for maintenance and adjustments.
Capping turret for plastic screw flat caps – Used Hot Filling Triblock
Capping unit suitable to apply plastic screw caps on one format of PET bottle.
This version of capper was born to satisfy the request of many customers that, in the actual line of bottling, ask for machine that are ready for frequent wash.
The parts of this kind of cappers, exposed to the chemical agents using to wash the line, are in iron stainless steel:
- top cover of the capper;
- external protection (carter);
- pistons supports flange;
- magnetic heads protections;
- mechanical protection (against water) between the washable part and the no washable part (the upper part with gears, cam, bearings,…etc.);
- bottle neck guide;
- colon of the bottle neck guide;
- bottle neck support;
- pick and place system;
- the cover of the pick and place system.
Complete Standard Rinser-filler-capper Machine Unit Executed With:
- Complete with parts in contact with the product in s/s Aisi 316L
- Pump for automatic centralized greasing
- Rubber pads rinsing by means of chlorinated water spray nozzles
- device for anti-splash on transfer star from filler to capper
- Set of Dummy Bottles for closed circuit sanification designed for inserting into the valves with a quick manual operation.
- UV Cap Device at Cap Chute
- Bottles neck finish rinsing by chlorinated water before capping turret
- Machine executed to allow Automatic CIP. This comprises the pneumatic valves to and from the CIP unit on the machine pipes and the electric control mechanisms. The system ensures the utmost efficiency in terms of safety and precision in the machine sanitizing phases.
Piston Filler Turret Executed With:
- Stainless steel AISI 316 for parts in contact with product
- Level control by probes (see attached Technical information sheet “D”)
- Three way valve
- Temperature probe
Accessories Included In The Machind Base Price:
Speed automation of Used Hot Filling Triblock
Manages the filler speed, according to the bottle flow upstream and downstream the filler. A set of photoelectric cells, installed at the machine infeed and outfeed, monitors the consistency of bottle supply and discharge.
Electronic Unit for Pressure and Level Separate Control.
On the upper side of the tank are the pressure transmitter and product level controller. The system permits optimizing the flow of gas and product into the tank by independent programming.
Automatic Washing Plant for Bottle Bursting.
This removes bottle debris from the valves and lifters automatically. High-pressure water jets are instantly activated when a bottle bursting occurs. A supplementary cam keeps the bottle-centering gasket device raised to wash the mouth seal efficiently.