Unique aseptic program from KHS now complete
New Innosept Asbofill ASR rotary aseptic machine closes the gap
Thomas Niehr*Paul-Uwe Winterhoff**
KHS is completing its machine portfolio for aseptic beverage filling in time for drinktec 2013, thus providing the ideal aseptic filling system whatever your aseptic application. KHS first modernized its successful linear aseptic machine program with the introduction of the second generation of Innosept Asbofill ABF machines. Since the new generation's launch to market machine sales in this segment have risen considerably, with the TWIN version also contributing to these positive figures. Just recently KHS presented the Innosept Asbofill ESL or extended shelf life variant specially designed for the filling of still, non-alcoholic beverages for the cold chain. The extensive expertise gleaned from internationally acclaimed Innosept Asbofill ABF technology has gone into the ESL's makeup, thus the ABF and ESL have much in common. The same goes for KHS' latest development in aseptic equipment: the recently introduced Innosept Asbofill ASR rotary aseptic filling machine. Here, too, Innosept Asbofill ABF processes and components that have proved themselves in practice have been utilized. With the Innosept Asbofill ASR KHS is now closing the final gap in the area of aseptic cold fillers – which will prove a boon to bottlers of liquid dairy products and non-alcoholic beverages. With its range of linear and rotary systems the company can now give the industry a full aseptic program that leaves nothing to be desired.
Perfectly prepared for all kinds of tasks
The Innosept Asbofill ABF 611 and Innosept Asbofill ABF 711 linear aseptic filling machines are predestined for bottling capacities of up to 12,000 plastic containers per hour and a bottle surface hygienization of up to log6. In the extended shelf life segment the corresponding Innosept Asbofill ESL 611 and Innosept Asbofill ESL 711 offer bottlers a surface hygienization of up to log5. The difference between the 611 and 711 series lies in the type of bottle to be processed; machine type 611 handles plastic bottles holding between 100 and 750 ml, with the 711 designed for volumes of 0.25 to 2 liters as standard.
*Head of Aseptic Filling Technology, KHS GmbH, Bad Kreuznach, Germany.
Phone: +49 671 852 2900
**Head of Aseptic Filling Technology Design Engineering, KHS GmbH, Bad Kreuznach, Germany. Phone: +49 671 852 2902
The original machine output of both the Innosept Asbofill ABF and the Innosept Asbofill ESL can be doubled by the TWIN concept, raising the capacity to up to 24,000 plastic bottles per hour. At outputs like these this is where new Innosept Asbofill ASR rotary aseptic technology comes into play. The Innosept Asbofill ASR can process filling volumes from 250 ml to 1.5 liters with two different capacities available. The two Innosept Asbofill ASR 24 machines output 24,000 bottles per hour holding either up to 500 ml or up to 1 liter; the three Innosept Asbofill ASR 36 models are able to process 36,000 bottles per hour for the above two volumes plus a third bottle size of 1.5 liters maximum.
Full consultancy given in advance
KHS gives prospective customers detailed advice from one source on whether linear or rotary equipment would better suit the required applications at their beverage plant. Criteria such as the product to be filled, the frequency of product and bottle changeovers, production cycles and the like are examined in detail prior to investment. KHS completes the service by recommending which aseptic systems would be particularly beneficial to the client. Linear aseptic filling machines generally cover a low to medium output range, with rotary aseptic machines catering for the higher capacities. If a fruit juice company nearly always fills the same type of bottle at rates of at least 24,000 bph with very few product changeovers, a rotary machine would be the aseptic system of choice, for example. However, if bottle types are changed several times a day, a linear aseptic machine would be better. The reason is that changeovers are faster and easier on linear machines than on rotary machines. On the Innosept Asbofill ABF, for instance, the plastic bottles are fed through the entire machine in one single holder. There's no need to switch from one carousel to the other – as is the case on the rotary system. All conceivable conversions and replacements take place in the unsterile area outside the aseptic zone, with the bottle neck conveyed solely in the sterile zone. Even when extremely sensitive products such as milk are bottled, the linear aseptic filler is usually first choice, with its small aseptic zone of less than 1.5 m3 an added bonus. The small sanitary rooms on the new Innosept Asbofill ASR are also setting standards in this segment, however, and becoming more like the linear machines in this respect. With zones of 10 m³–13 m³, depending on the machine size, the sterile area on the rotary machine has become much smaller.
With high outputs in particular the Innosept Asbofill ASR is usually the best machine to go for; at speeds of over 24,000 bottles per hour and large production batches rotary technology has many advantages. KHS' full program of equipment allows bottlers to select the perfect design for their production setup.
Tried-and-tested technology
It's not uncommon for companies devoted to aseptic cold filling to utilize both linear and rotary machinery for various applications. The general rule is that very different parts and technologies are used for these various pieces of equipment. Not at KHS. Where possible KHS has made use of tried-and-tested components from the Innosept Asbofill ABF portfolio for its new generation of Innosept Asbofill ASR rotary machines. This not only has the advantage that very few spare parts need to be stored but also that operating and maintenance personnel can be quickly trained to work on the new system.
Integrated valve manifold
As in the linear technology the new generation of Innosept Asbofill ASR rotary machines has an integrated valve manifold with identical functions which is installed on the machine to save space. The practice on rotary machinery to date was to use a separate valve manifold.
Room-within-a-room concept
On the Innosept Asbofill ASR, too, development has focused on aseptic safety, with the new rotary technology based on the proven room-within-a-room concept implemented in the ABF series. Specific measures protect the minimally dimensioned aseptic zone from the surrounding machine area which in turn forms a mechanical barrier to the production shop. The aseptic zone on a lot of rotary equipment is often only shut off from the production shop by its cladding. There is no machine area to act as a buffer, with the result that very elaborate seals and framed windows made of safety glass are required to separate the sanitary room from the production shop for product safety. KHS has a different solution here, with its room-within-a-room concept applied to the entire Innosept Asbofill portfolio and thus providing maximum standards of safety. The surrounding machine area can be opened for any necessary work even during production without endangering the sterile conditions prevalent in the integrated aseptic zone.
Reliable sterilization with H2O2 aerosol
The Innosept Asbofill ASR adopts the same principle of sterilization as its linear aseptic counterparts and also has an identical aerosol and heating system to the Innosept Asbofill ABF. In the sterilizer H2O2 aerosol enters each plastic bottle through a lance inserted in the bottle that ends just below the neck. On the Innosept Asbofill ASR the plastic bottle is lifted to its exact position in relation to the fixed lance. Spraying the aerosol into the bottle ensures that all areas of the bottle are covered in H2O2, reliably sterilizing even ribbed, embossed, and square bottles and bottles with very structured surfaces. A two-channel system is created in the neck, where H2O2 aerosol is sprayed into the center of the bottle and the gas this displaces escapes up the sides of the lance and out of the bottle. Depending on the shape and size of the bottle the H2O2 used for sterilization enters the unheated bottle at a temperature of about 100°C, completely covering the inside of the bottle in a sterilized film. On the Innosept Asbofill ASR the bottle exterior is sterilized by H2O2 being directly sprayed onto the bottle wall.
Residue-free drying
The special sterilization principle applied enables the H2O2 to dry within a single drying carousel without leaving any residue. On the previous version of this machine two drying carousels were needed. The advantages of the new design are that less space is required, the aseptic zone is smaller, the energy consumption is minimized, and the maintenance effort is reduced.
Controlled supply of sterile air
Sterile air is blown permanently into the aseptic zone between the drying and filling carousel. A positive displacement current transports the sterile air towards the machine infeed and discharge and thus prevents germs from entering the machine. The valve manifold positioned on the machine supplies the sterile air. As in the ABF linear machine series sterile candle filters are used instead of HEPA filters, each of which is sterilized with steam before production starts.
A suitable filling method for every product
A non-contact filling system is used in the ASR series, with operators able to choose between two different types of filling valve. Here, too, KHS is able to advise on the best filling valve for the customer's range of products. It's interesting to note that compared to older ACF rotary filling technology the filling carousel on the new Innosept Asbofill ASR machines is much smaller thanks to optimization of the filling processes. The new system enables around 30% fewer valves to be utilized at the same filler speed. The result? Lower investment costs, less space needed, a smaller aseptic zone, and fewer maintenance measures.
Capper area greatly modified
It's usual for rotary aseptic equipment to have the entire capper unit contained in the aseptic zone. On the new KHS rotary setup, however, only the cone of the capper heads is now in the aseptic area – as in the ABF series. All other components are in a separate sanitary room which is separated from the main aseptic zone by an airlock. This keeps major interfering elements out of the sterile zone, with the safety aspects of linear machines now applied to rotary technology. This means that the aseptic zone can again be smaller – which in turn yields a number of benefits. Another plus point of the new Innosept Asbofill ASR is the cap sterilizer which has also been completely redesigned. The unit is extremely compact and incorporated into the machine as a fixed component. Long, sterile tunnels with all the risks these entail are now a thing of the past.
Bottle sterilization like cap sterilization
On the Innosept Asbofill ASR the plastic caps travel straight from the sorter into a feed chute. The caps are sterilized in exactly the same manner as the plastic bottles; here, H2O2 aerosol is sprayed onto the caps and then allowed to take effect and dry. This process again utilizes tried-and-tested practices from the ABF series. The Innosept Asbofill ASR can also process sports caps as an option.
Optional servo capper
Another option for the ASR series is to equip it with a servo capper where each capping element has a servo drive for capping. These servo-controlled motors are activated by a central computer and are capable of generating any desired speed and any desired capping torque regardless of the machine speed. Capping torques for individual closures can be stored in the system and are automatically set when the relevant product is selected. There is no mechanical intervention. The lifting motion of the capping head is also servo driven, meaning that lifting cams with all their disadvantages can be dispensed with.
Many additional monitoring functions
Constantly monitoring each and every production detail is becoming increasingly important. To this end the Innosept Asbofill ASR can be fitted with a number of additional options if required. These include the newly introduced media monitor which is available for all Innosept Asbofill machines. Here, metering devices control the use of various media such as product, H2O2, and cleaning fluids etc.with the utmost precision. All relevant input and output parameters are logged at the machine interfaces. Another option is bottle tracking with the help of which operators can see which sterilizing head has sterilized which bottle, which filling valve has filled it, and which capper head has sealed it. The relevant code is printed onto the bottles directly downstream of the aseptic process.
A production data acquisition system can also be separately ordered which documents all process data in full detail. Each valve motion, and each temperature and pressure graph are permanently recorded. If the filling line has a manufacturing execution system or MES the machine's production data acquisition system can simply be connected up to this for the transfer of all relevant MES data.
The Innosept Asbofill ASR can of course also be kitted out with the KHS remote diagnosis system ReDiS which, through remote access to the machine controller, often avoids the need for on-site service.
A drop of nitrogen of great benefit to lightweights
Another possible option is to place a drop of liquid nitrogen in the head space of the filled plastic bottles. This procedure is especially recommended where very lightweight plastic bottles are to be filled. The reason is that adding liquid nitrogen causes the pressure inside the plastic bottle to build up, thus giving the bottle greater stability and making it easier to process down the line, such as in the labeling area, during palletizing, and also when being transported. An additional positive aspect of this process is that it displaces the oxygen in the bottle head space.
The neck conversion package
A neck conversion package is also being planned. Customers who opt for the neck conversion package profit from being able to fill both the plastic bottle with a 38-mm neck classically used in aseptic practices and those with a 28-mm neck diameter along with rapid changeover times. Establishing two sterilization units with an integrated switch for different types of closure is also feasible. If this option is included, operators can change between various types of closure at the simple press of a button.
Monoblocking with a stretch blow molder available on request
The Innosept Asbofill ASR program is to include a monoblock version of the filler with the InnoPET Blomax Series IV stretch blow molder. Whether to choose this monoblock system or not depends on the products to be processed and the plant's production conditions. In the monoblock version the air conveying segment is replaced by a transfer module which combines the stretch blow molder with the rotary aseptic machine. Besides specifically saving on the space needed for the air conveyor, the system also has the advantage of even gentler bottle handling. Accumulation pressure that can occur when plastic bottles are air conveyed is no longer an issue, simplifying the processing of lightweight plastic bottles in particular. Whether a monoblock setup is suitable or not depends on the relevant conditions of production which must be carefully checked in each individual case. KHS provides support here.
Specified cleaning cycles
To ensure that the Innosept Asbofill ASR always operates at the maximum level of microbiological safety the necessary regular cleaning process is fully automatic. As in linear technology the aseptic zone is given a foam and gel clean prior to production which is gentle on materials. Every single point in the sterile zone is reliably sanitized. After the cleaning agent has been rinsed out and the aseptic zone allowed to dry, it is sterilized with H2O2. Introducing the Innosept Asbofill ASR means that regular interim sanitizing is also no longer necessary on rotary machines.
Full personnel training included
In the world of aseptic beverage filling everybody has to keep consistently to the given rules. KHS holds training courses for all those involved in line operations to specifically hone this awareness. Likewise involved is the management whose prime task is to continuously motivate its employees to consistently adhere to all implemented hygienic measures. KHS purposely pursues a strategy of familiarizing employees with the aseptic line equipment at a very early stage. Those responsible for the line are usually already on board during the final assembly phase at the plant. This is when a basic course on microbiology is also held and operators are taught about the individual components and how to work 'their' machine. This gives them a feeling for the line and an understanding for aseptic filling. In an ideal situation operators are also present at the installation and commissioning of aseptic systems. After production startup KHS stays on site for several more days to help and train up the operating personnel to work on the aseptic line.
The right concept whatever the application
To sum up, with its new Innosept Asbofill ASR rotary aseptic technology KHS is now the only manufacturer to provide the beverage industry with a full program of both linear and rotary machines for aseptic filling. The motto is to have the right concept whatever the application. What's especially beneficial is that tried-and-tested processes and components have been utilized for both KHS' linear and rotary technology, ensuring essential hygienic safety on all counts. The easiest way of obtaining excellent safety and economy is to choose a system that is perfectly tailored to your production conditions – a system that can always be found in the portfolio of KHS Innosept Asbofill machines.
