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無菌灌裝線
The comparison between traditional PET filling machine with new Asepsis cold filling technique
Although PET asepsis cool and (hot) filling machine is developing not long time, but few famous beverage and beer manufacturers have already mature asepsis cold filling art. Compare with filling art, the traditional hot filling have two kinds. One is high temperature hot filling , the other is middle temperature hot filling. Its working theory is that after filling it will be high temperature arrives at 65℃~75℃ through pasteurization. This two kind way no need to sterilization only for bottle cap lonely. It only need the products keep long time in high temperature and finished sterilization for cap and bottle. Asepsis cold filling first should be sterilization for cap and bottle, then filling under the asepsis condition, till full sealing completely, then the bottle will leave the asepsis condition.
Compare with the two arts flow chart, the biggest difference is that the beverage heated time differences. As we know, the long time heater during beverage producing line, it wills worse affect on the quality and fresh of drinks. While the aseptic cold filling adopt UHT Ultra-high temperature sterilization only need less than 30 seconds. And also it can keep sterilization affect during high temperature. While hot adopt the sterilization way makes material keep long time high temperature condition, it will serous affect the fresh and color and the content of nutriment（vitamin）.
Otherwise, from the producing line equipments, when filling come across stopped, adopt hot filling way deal with material, some return filling will keep long time hot, this will affect the whole products quality. While the asepsis clod filling will not come out this phenomenon, the material across the instantaneous sterilization then downed room temperature, then stored in asepsis tank without affect quality.
The comparison between PET bottles, from above filling arts, we can see that the two kind of filling way are difference requirements for PET bottle. The hot filling art require PET bottle can endure 85℃~92℃ high temperature on changeable. Then it require enlarge PET material’s crystalline. At the same time, when it blows the bottle, it will restrict the energy of abduction. The PET bottle has these features: the bottle thickness wall, there are specific ribs of bottle can stop hot shrinkable, it also require with rime bottle gate and so on. Then it can restrict the design free time. The aseptic cold filling can use light bottle (the highest temperature 60℃) and standard cap. Then it can reduce down the cost of bottle and cap, you also can choose freely design for this bottle.
The aseptic cold (hot) filling art features
During the hot art, beverage keep long time in high temperature, the general bacterium and microbe will be killed. Then it also need add antiseptic, this beverage security is high. How to keep security of beverage of the beverage? The most important is building the aseptic condition and protection. Compared with hot filling, the aseptic cold ( hot ) filling adopt UHT ultra-high temperature instantaneous sterilization to kill material, then the material heat short time and losing the low nutrition. Then fresh and quality will not change clearly. The recently aseptic cold (hot) filling art can concert pasteurization and go along with cold producing line to produce. Then it cans loss the lower nutrition of material and also the security of products can be kept.
The material of package aseptic is the key step during the aseptic cold (hot) filling art. Due to PET material is not heat-resistant, then it only can use chemical reagent to sterilization. If you want to keep sterilization of bottle and cap, and also you don’t allow the chemical reagent to affect the material. The aseptic filling was adopting these measures: it need the beginning blown bottle quantity is less than 5cf/bottle. The conveyor bottle adopts aseptic air with air conveyor belt, the inner bottle adopts PAA to be sterilization and arrive high affection (7log), at the same time, and it is sterilization for outside of bottle. The disinfector have automatic reclaim and the test system of concentration, it keep disinfector stable. Then it use aseptic water washing clean the rudimental disinfector in bottle, then it use aseptic air blow dry and then keep rudimental disinfector is not affect for material, bottle cap adopt the way of disinfector marinate to be sterilization. It has a good affect sterilization by controlling marinate time.
The main equipment of Aspects cold ( hot ) filling are allowed to suitable for design. It has advantage for skills at pump and valve, the face smooth at material; the main parts face design and choosing the resistance rusty material and so on. it also brings automatic ( CIP )system, sterilization system and outside of equipment foam clean system, except that, aseptic cold filling with its own special aseptic filling valve, all these systems keep clean of materials. And it can not come out secondary pollution.
Due to after cold filling, the PET bottle will not shrink, then during the material and cap will have air, so some oxygen will stay and oxidize the material, then it can cause the material go bad. So aseptic cold filling will add one nitrogen (other inert gas) displace system, which can blow the air on top and keep material is not oxidize
Aseptic space keep, it often adopt clean and isolation measurements. The mail filling designed D100 grade air clean. Outside have 10-thousand-grade clean system ( some aseptic system is not inquire this ), it through the clean filter system, which enable filling condition air clean rate, then it will not be secondary pollution by air microorganism.
About the middle drink, it can not use hot filling art to produce. Due to it adopt falling bottle way to sterilize, carbonic acid drinks also can stop increase of microorganism and neutral drink can not keep products safety. If you use hot filling art tea drink and you must add aseptic. While aseptic cold (hot) filling, it is produced under aseptic condition, so it suitable so strength, it can suitable for a wide range drinks, including the neutral tea drinks, dairy drinks and other kinds of drinks, it only adjust before equipments it can suitable for products type.
The operating staff, as we know that in the whole operation system, the operator is the biggest pollution source. The design air purification clean the air at the same time, it reduce the pollution of operator. When the operator goes into the super 10-thousand-grade clean system air purification, it need through spray pump sterilize. While the 100 grade purification design small and utility. It can enable the operator to operate and don’t broke down the aseptic condition. The inner face of purification equipment can automatic clean and sterilize.
The management, drink aseptic skills contains high technology, it need high-level skills person and manager to management unify. It often adopts HACCP management system. All the management all need form film system and also need special person carry out to operate. Only we do normal management, we can keep aseptic cold filling safety in fact.
The original material and producing line cost compare
It has big differences between two kind of producing line, aseptic cold filling used blown bottle speed quickly, low power consumption. While the hot blow bottle’s seed is slowly and big power consumption. Under the same producing line condition, invest cold filling blow bottle high price than hot filling (not including the bottle brown equipment). Aseptic cold filling art complex, filling assistant equipment is more. Compare from the whole, one aseptic filling producing line beginning invest is high than hot filling producing line.
From material cost, it main is that two kind of bottle quality difference large. Save material and down cost. Duo to hot filling PET bottle lip require special, the two kinds of caps are differences.
From cost of operation, aseptic cold filling have one Disinfectant consumption, but the whole cost is low than hot one. While the seed is better quicker, the quantity is better higher, the cost is better low.
Through comparison, we can see that cold aseptic cold ( hot ) filling beginning invest is large, but duo to cold ( hot ) filling material cost and operation cost is low, so we can quickly return high parts invest. With equipment time enlarge, aseptic cold (hot) filling cost advantage can obvious expression.
Conclusion
The traditional drink hot skills and aseptic cold filling technology is adopting wide range now. From the technology, they have their own advantages. While the traditional hot art mature, products risks low. The operation is easier, it also no high requires for operator. But at the drinks fresh, it has disadvantage can not be resolved completely. Aseptic cold (hot) filling skills requires complex, products are with risks. But at the fresh and nutrition, it has advantages than hot filling. It has wide range prospective during the future market. We can see that, as the Modern filling technology to improve and mature, the cold (hot) filling will displace hot filling producing line and become the main way of drink package business.
John Chen
HONG GUAN MACHINERY CO.,LTD
www.fillermachine.com
Our products are as following:
Integrate systems of Liquid Processing
2,000 ~ 36,000 BPH / PET, Glass Bottle for Tea (Juice) Hot Filling Line.
2,000 ~ 48,000 BPH / PET, Glass Bottle for Carbonated Soft Drink Filling Line.
3,000 ~ 36,000 BPH / for Mineral Water Filling Line.
3,000 ~ 48,000 BPH / PET, Glass Bottle for Beer Filling Line.
2,000 ~ 30,000 BPH / Beverage and Aluminum Can Beer Filling Line.
2,000 ~ 18,000 BPH / for Concentrate liquid, (Sauce) Filling Line.
A. HOMOGENIZER 250L--20,000L/HR
B. Bottle Rinsing Filling Machine
C. High Viscosity Liquid Filler(Piston Filler)
D. Conveyor System
E. CIP System
F. UHT (Tubular & Plate Type)
Manufacturing of Single Equipment for Packaging Line
A. Bottle Rinser Filler Capper(Monoblock)
B. Automatic Filler, Aluminum Foil Capper & Sealer
C. Case Packer Un Packer
D. The whole packing facilities of mineral water
E. The whole plant for juice Equipment
F. The whole plant for Milk Equipment
G. Packing Machine (Case Packer Shrink Wrapper & Wrapper Around)
E. Crate Washer
I. High & Low Level Bottle Depalletizer/Auto Palletizer
J. Ice Cream Plant
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SKYPE: johnchenboss
Cell No. 86-13818831943,886-935435587
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Best regards,
John
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