Latest Aseptic Filling Technology
2018-06-08 08:01:20
On February 26-27 this year, SIG Group held a sterile technology seminar in Jinan. The SIG Group's SIG Combibloc, Simoneta, Cobolas and Manzini introduced the aseptic packaging technology for liquid foods. Its related topics. During the conference, the company also visited Jinan Jiabao Dairy and Huiyuan Laiwu Beverage Factory. Now I have gathered several aspects of this seminar that I feel are deep in, and I will serve as a member of the Beverage Association.
SIG Simone Aseptic Filling Technology
SIG's design philosophy is "The design of the machine should meet the requirements of sterility, rather than relying on the establishment of a sterile area to meet the needs of the machine." Its basic point is the stability of various technical indicators when the machine is in continuous operation.
The second-generation rotary PET bottle aseptic filling machine developed by SIG Simonasi was a major innovation in the original 124m3 overall sterile room that contained the bottle disinfection-washing-filling-capping.
The new generation sterile field has a volume of only 9m3, and its seal abandons the traditional mechanical seal and adopts fluid dynamic sealing. The ring-shaped aseptic zone fills the valve body and the flow meter, and the drive of the machine is excluded from the aseptic area, thereby reducing the amount of disinfectant, saving time for disinfection of the sterile field, and minimizing the time The contamination of the disinfectant with the operator also facilitates the maintenance of the mechanical parts.
Some cleaning nozzles are arranged on the rotating body of the filling machine and the fixing chamber of the sterile room to wash and disinfect each other.
The bottle enters the washing machine and is clamped by the bottleneck gripper and inverted. Peracetic acid sprays the inverted PET bottle in an all-round manner. The sterilization efficiency reaches log 6; it is rinsed with sterile water and then sprayed with nitrogen to make the bottle. The air volume was reduced to 5%, and the hydrogen peroxide residue was less than 0.5 ppm.
In control technology, using infrared signal transmission technology, the flow of each filling valve is controlled by the flow meter so that it can measure the liquid flow through the filling valve at any time during the filling process.
Linear sterile system
The operation process of the SIG Simonexi linear aseptic filling machine is as follows: After passing through the air, the bottle machine is grasped by the robot and sent to the machine's bottle-neck conveyor belt, which can enter 10 bottles at a time.
The bottle enters the disinfection zone and is sprayed with 35% concentration of vaporized hydrogen peroxide in the vacuum chamber in the vacuum chamber beforehand. After a certain reaction time, the residual vapor is extracted through the second evacuation, and the heat is introduced. The bottler is blown dry with sterile air; the juice is filled for 2 times to the specified capacity, the injection volume is not in contact with the bottle device by the flowmeter-controlled filling valve, and liquid nitrogen can be injected after filling if necessary to fully eliminate it. Oxygen; sealed with aluminum-plastic film, after which the bottle was removed from the aseptic area and twisted open.
From the start of bottle disinfection until the bottle is sealed, the upper area of ​​the bottle mouth is a sterile area, the bottom is a non-sterile area, and the space of the sterile area is only 1.5m3. The system should be CIP after 48-72 hours of continuous operation.
Before the start of production, the system was sterilized with steam at 121°C. After sterilization, the system was sterilized with sterile air and then sprayed with a hydrogen peroxide solution at 70°C. After a short pause, it was dried with hot air. The steaming station was sterilized with steam at 120°C-130°C.
The linear aseptic filling machine is suitable for infusing high-acid or low-acid juice or milk, and can be used for bottles made of PET or HDPE (high-density polyethylene) materials. The machine's production capacity is 12000BPH, product sterilization rate of LOG6, shelf life of 6-12 months, beverage products have entered the market.
PET bottle plasma coating technology
PET bottle is widely used due to its light weight, transparency, and no breakage. It has a variety of bottle shapes and is easy to seal and store. The material is recyclable and widely used. The current consumption of PET bottles is close to 800 billion. However, the air permeability of a thick PET bottle generally results in the oxidation of vitamin C in the content or the loss of CO2 in the nitrogen-filled beverage. Therefore, the improvement of the barrier properties of the PET bottle has attracted attention in various countries.
The specific method of plasma coating technology to improve the barrier properties of PET bottles introduced by Mr. Chen Juntian of SIG Cooperas Corp. is: placing PET bottles in a closed coating chamber, exhausting to a vacuum state, and injecting a type containing Si atoms. The chemical gas is injected into O2 at the same time, and the microwave is applied to make the gas pulse and chemical reaction so that SiO2 is deposited on the wall of the bottle and its thickness is only 15Nm. Visually observing the transparency of the coated PET bottle before coating was no different.
The first rotating multi-station plasma coating equipment produced by the Cooperras company has been put into commercial operation at the Bischofszell Foods plant in Switzerland. The machine is connected to a bottle blowing machine and an aseptic filling machine to produce 0.4-1L of fruit juice beverage. The output reaches 10000BPH. The coated bottle can be used for hot filling at 95°C and aseptic cold filling; it can be filled with juice drinks, carbonated beverages such as beer. The coated PET bottle had a 27-fold improvement in the barrier factor and a 17-fold increase after cold-filled juice. After being stored at 20°C for 26 weeks, the vitamin C in the juice dropped from 450 ppm to 220 ppm. After the fruit juice was hot-filled at 89°C, the barrier element was improved 7-10 times. This technology has been approved by the US Food and Drug Administration FDA and the European Union.
Research on Bellows Heat Transfer Technology
Conventional wisdom is that when liquids are heated and cooled in a bellows in a tubular heater, the bellows will enhance the turbulent flow of the fluid and thus increase the overall thermal coefficient. This is the main reason that most tubular UHT or HTST systems use bellows. in accordance with. Mr. Gerardo's seminar presented the results of a study by SIG Manzini and the University of Parma, Italy, on the heat transfer technology of bellows and smooth tubes in tube heat exchangers.
It is considered that when the milk or juice with low viscosity is heated and cooled by a bellows or a smooth tube in a UHT system, the total heat transfer coefficient of the fluid in a turbulent or turbulent flow state is relatively close, and the pressure drop of the liquid in the bellows is relatively small. (pressure loss) is significantly greater than the smooth tube. For the heating and cooling of viscous material, when in the transitional flow, the total heat transfer coefficient of the bellows is significantly larger than the smooth tube, which is due to the agitation effect of the undulating ripples on the viscous material. The pressure drop of the viscous material in the bellows is greater than the smooth tube. This research conclusion has certain significance for the UHT equipment selection of fruit and vegetable juice processing.
SIG Simone Aseptic Filling Technology
SIG's design philosophy is "The design of the machine should meet the requirements of sterility, rather than relying on the establishment of a sterile area to meet the needs of the machine." Its basic point is the stability of various technical indicators when the machine is in continuous operation.
The second-generation rotary PET bottle aseptic filling machine developed by SIG Simonasi was a major innovation in the original 124m3 overall sterile room that contained the bottle disinfection-washing-filling-capping.
The new generation sterile field has a volume of only 9m3, and its seal abandons the traditional mechanical seal and adopts fluid dynamic sealing. The ring-shaped aseptic zone fills the valve body and the flow meter, and the drive of the machine is excluded from the aseptic area, thereby reducing the amount of disinfectant, saving time for disinfection of the sterile field, and minimizing the time The contamination of the disinfectant with the operator also facilitates the maintenance of the mechanical parts.
Some cleaning nozzles are arranged on the rotating body of the filling machine and the fixing chamber of the sterile room to wash and disinfect each other.
The bottle enters the washing machine and is clamped by the bottleneck gripper and inverted. Peracetic acid sprays the inverted PET bottle in an all-round manner. The sterilization efficiency reaches log 6; it is rinsed with sterile water and then sprayed with nitrogen to make the bottle. The air volume was reduced to 5%, and the hydrogen peroxide residue was less than 0.5 ppm.
In control technology, using infrared signal transmission technology, the flow of each filling valve is controlled by the flow meter so that it can measure the liquid flow through the filling valve at any time during the filling process.
Linear sterile system
The operation process of the SIG Simonexi linear aseptic filling machine is as follows: After passing through the air, the bottle machine is grasped by the robot and sent to the machine's bottle-neck conveyor belt, which can enter 10 bottles at a time.
The bottle enters the disinfection zone and is sprayed with 35% concentration of vaporized hydrogen peroxide in the vacuum chamber in the vacuum chamber beforehand. After a certain reaction time, the residual vapor is extracted through the second evacuation, and the heat is introduced. The bottler is blown dry with sterile air; the juice is filled for 2 times to the specified capacity, the injection volume is not in contact with the bottle device by the flowmeter-controlled filling valve, and liquid nitrogen can be injected after filling if necessary to fully eliminate it. Oxygen; sealed with aluminum-plastic film, after which the bottle was removed from the aseptic area and twisted open.
From the start of bottle disinfection until the bottle is sealed, the upper area of ​​the bottle mouth is a sterile area, the bottom is a non-sterile area, and the space of the sterile area is only 1.5m3. The system should be CIP after 48-72 hours of continuous operation.
Before the start of production, the system was sterilized with steam at 121°C. After sterilization, the system was sterilized with sterile air and then sprayed with a hydrogen peroxide solution at 70°C. After a short pause, it was dried with hot air. The steaming station was sterilized with steam at 120°C-130°C.
The linear aseptic filling machine is suitable for infusing high-acid or low-acid juice or milk, and can be used for bottles made of PET or HDPE (high-density polyethylene) materials. The machine's production capacity is 12000BPH, product sterilization rate of LOG6, shelf life of 6-12 months, beverage products have entered the market.
PET bottle plasma coating technology
PET bottle is widely used due to its light weight, transparency, and no breakage. It has a variety of bottle shapes and is easy to seal and store. The material is recyclable and widely used. The current consumption of PET bottles is close to 800 billion. However, the air permeability of a thick PET bottle generally results in the oxidation of vitamin C in the content or the loss of CO2 in the nitrogen-filled beverage. Therefore, the improvement of the barrier properties of the PET bottle has attracted attention in various countries.
The specific method of plasma coating technology to improve the barrier properties of PET bottles introduced by Mr. Chen Juntian of SIG Cooperas Corp. is: placing PET bottles in a closed coating chamber, exhausting to a vacuum state, and injecting a type containing Si atoms. The chemical gas is injected into O2 at the same time, and the microwave is applied to make the gas pulse and chemical reaction so that SiO2 is deposited on the wall of the bottle and its thickness is only 15Nm. Visually observing the transparency of the coated PET bottle before coating was no different.
The first rotating multi-station plasma coating equipment produced by the Cooperras company has been put into commercial operation at the Bischofszell Foods plant in Switzerland. The machine is connected to a bottle blowing machine and an aseptic filling machine to produce 0.4-1L of fruit juice beverage. The output reaches 10000BPH. The coated bottle can be used for hot filling at 95°C and aseptic cold filling; it can be filled with juice drinks, carbonated beverages such as beer. The coated PET bottle had a 27-fold improvement in the barrier factor and a 17-fold increase after cold-filled juice. After being stored at 20°C for 26 weeks, the vitamin C in the juice dropped from 450 ppm to 220 ppm. After the fruit juice was hot-filled at 89°C, the barrier element was improved 7-10 times. This technology has been approved by the US Food and Drug Administration FDA and the European Union.
Research on Bellows Heat Transfer Technology
Conventional wisdom is that when liquids are heated and cooled in a bellows in a tubular heater, the bellows will enhance the turbulent flow of the fluid and thus increase the overall thermal coefficient. This is the main reason that most tubular UHT or HTST systems use bellows. in accordance with. Mr. Gerardo's seminar presented the results of a study by SIG Manzini and the University of Parma, Italy, on the heat transfer technology of bellows and smooth tubes in tube heat exchangers.
It is considered that when the milk or juice with low viscosity is heated and cooled by a bellows or a smooth tube in a UHT system, the total heat transfer coefficient of the fluid in a turbulent or turbulent flow state is relatively close, and the pressure drop of the liquid in the bellows is relatively small. (pressure loss) is significantly greater than the smooth tube. For the heating and cooling of viscous material, when in the transitional flow, the total heat transfer coefficient of the bellows is significantly larger than the smooth tube, which is due to the agitation effect of the undulating ripples on the viscous material. The pressure drop of the viscous material in the bellows is greater than the smooth tube. This research conclusion has certain significance for the UHT equipment selection of fruit and vegetable juice processing.
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