New aseptic filler for beverages cuts the requirement for cleanroom space
Filling equipment supplier KHS is offering the beverage industry a ground-breaking innovation in the form of ACF equipment that operates according to the process of wet sterilisation in a mini-isolator based on proven components.
The key advantage of the new solution is that implementing a mini-isolator reduces the required cleanroom volume significantly. Highest quality standards can be achieved with shorter cleaning phases and lower energy and sanitising costs than in the past. Another factor is that the new solution takes up minimal space.
The new ACF system is able to process a range of plastic bottle styles and gentle bottle treatment is guaranteed. The system is able to process all bottle sizes from 100 ml to 3 L. The maximum processing capacity is 48,000 plastic bottles/hr.
During the rinsing process, the plastic bottles are turned upside-down in the transfer star before entering the rinser and are returned into their original position in the outfeed star. This approach has made it possible to design a smaller rinser carousel. For example, while a 140-station rinser was previously required for processing 30,000 plastic bottles/hr, a 100-station rinser is now sufficient. This enables KHS to use a single rinser within the ACF monoblock even for small cleanrooms.
Compared with several rinsers, a single rinser approach has the advantage that fewer transfer stars are required, which reduces the number of dynamic/moving parts and decreases the strain on the modular units. In addition, it has a positive effect on line efficiency.
An electronically controlled Innoclean FR-DR-ACF triple-channel rinser is used as rinsing system for sterilising the interiors of plastic bottles. Various types of filling system can be integrated into the mini-isolator zone. The Innofill NV, for example, is used for aseptic cold filling of non-carbonated beverages, while the Innofill DNRV is a combined filling system designed for aseptic cold filling of both carbonated and non-carbonated beverages. The Innofill SV-ACF ACF servo capper is used as capping system.
The air control system from the dry KHS ACF solution is integrated into the new wet ACF concept. A flow of sterile air in the opposite direction to the bottle flow is produced in the rinser area. This ensures that peracetic acid gases and sterile air are conducted directly out of the cleanroom and evacuated on completion of the sterilisation process. An existing air lock helps to prevent all particles from entering the system from outside.
The flow of sterile air is conducted parallel to the plastic bottle flow in both the filler and capper areas as well as the bottle outfeed from the system. An air lock integrated in the outfeed area provides additional protection against entry of ambient air. A small amount of positive pressure prevails in the system at all times. Three HEPA filters integrated in the ceiling area ensure a continuous supply of sterile air.