Filling
technologies

Main | Diary and beverage plants | Filling
technologies

Filling
technologies

The decapper is designed to remove the cap from the returned bottles. The Plc manages all automatic and manual functions and allows to records statistics regarding the incoming bottles. This unit can be up-graded to recognize and discard potentially contaminated bottles. A combination of digital camera and fibre optic detectors allow to reject the bottles returned in the following conditions:

  • Bottles without caps
  • Caps without plugs
  • Caps with just the top part left
  • Caps partially opened
  • Not removed caps
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The leak tester is designed to recognize and reject leaking bottles. The working principle is to pressurize the containers for a predetermined period of time and measure the potential losses. The Plc manages all automatic and manual functions and allows to record statistics regarding the faulty bottles.

  • Reliable and accurate leak detection of cracks min. diameter of 0,2 mm
  • No bottle mechanical stress
  • Auto-rejection station
  • Touch-screen and microprocessor-based control
  • Robust stainless steel execution
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Washing machine for 5Gallons, manufactured in different sizes able to guarantee the highest level of bottle hygienic quality today on the market.

 Time for washing

 Temperature of washing

 Pressure of liquids

 Chemical %

 Mechanical actions

 

Time
 

The treatment time is the result of a washing cycle which can be customized in terms of number of stations and phases according to the customer standard and requirements. Our recommended washing cycle provides 6 main phases: 1. PREWASH - 2. DETERGENT - 3. FIRST RINSE - 4. SANITIZING - 5. SECOND RINSE - 6. FINAL RINSE


Temperature

The constant monitoring of the temperature is paramount in order to wash the bottles according to the preset values (between 60 and 65°C). An alarm stops the washer in case these set points are not respected. 

Pressure

To optimize the washing process, the washer is equipped with high pressure system, which:

  • Allows to increase the pressure of the washing jet up to 6 bar
  • Can be installed on one or more station of the washing phase
  • It's particularly indicated for difficult-to-clean bottles (hollow handles, shaped bottles)


Chemical %
 

In cooperation with the main multinational chemical company, we have developed a cleaning protocol in order to guarantee, after the washing treatment, a bottle consistent to the international hygienic norms and standards.

This protocol recommends specific products of different brand, suitable concentration and temperature of the solution (water + chemical product) for each phase of the washing cycle. 
 

Mechanical action

Neck Handling patented system to grip the neck of the bottle, guarantees important advantages as:

  • The possibility to use an high pressure washing jet
  • The washing of the external part of the bottle inside the washer, thanks to the possibility of the bottle rotation under the action of brushes
  • The washing of the bottle neck

Washing Rotating Nozzles is fitted with double washing rotating nozzles which guarantee the following advantages:

  • The jet of water hits not only the bottom, but the handle and the walls too.
  • The nozzles are self-cleaning (the water flow is inverted at the passing of each bottle) and the washing efficiency is therefore guaranteed. The disassembly for maintenance is considerably reduced.
  • The beam carrying the bottles is synchronized with the nozzle even in case of chain extension.

Rotary Brushing are motorised and clean the bottle externally. Since they make the bottle spin, the water jet hits not only the bottom but also the sides of the bottle.

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Fillers for still water in large containers fulfills the following requirements filling process avoids the contact between the valve and the neck of the bottle (risk of contamination transfer).

Filler consist of:

  • The filling process is electronically controlled to ensure into the bottle the predetermined volume of water.
  • The filling valve and all the piping, valves etc. in contact with the product have a sanitary design and are made of aisi 316 S.S.
  • All parts in contact with the product are prearranged for 3 or 5 steps CIP (cleaning in place) sterilization treatment.
  • The filling cabinet is equipped with overpressure air flow. A minimum class 1000 air filtration is guaranteed, so as to protect the filling environment from the external ambient contamination.
  • The washer and filler is "in block" in order to avoid the potential contamination of the clean bottles travelling from the washer outlet to the filling area.
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In order to satisfy the most strict hygienic demands, we offer an Ultra-clean monoblock with the following features:
 

Filling cabinet:

  • The filling cabinet has been reduced to the essential.
  • The cabinet is provided with HEPA filters.
  • The execution of the cabinet in aisi 316 without dead ends according to the strictest hygiene design requirements.
  • All mechanical and pneumatic gears have been installed outside the cabinet.
  • All surfaces are subjected to automatic CIP cleaning.

Capper:

  • The caps are treated with sterilized air before entering the high hygiene filling area.
  • The bottle leaves the filling room with the cap on top of the neck (nothing can contaminate the bottle).

 

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Our line can handle both the 3/5G and 5/10 Litres PET one-way bottles through a simple and quick change-over system able to combine minimum downtime together with maximum hygienic safety. 

Washer

  • Neck handling: 1 gripper for 2 pliers
  • Dedicated rinsing program for 5 litres one way bottles

Filler

  • Customized change parts to handle returnable and one-way bottle consistency
  • Dedicated filling program for 5Litres bottles

Capper

  • Electronic screw capper + press-on capper
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To obtain a good hygienic condition of the bottles, the first step is to sterilize the parts in touch with the product. This can be achieved through the CIP unit which can work in automatic or semi-automatic modality and with hot or cold solution.

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The electronic screw capper stands out because of its operating simplicity and precision.

  • The system doesn't require stars, mechanical clutches, or complex lifting mechanisms.
  • The closing torque can be set from touch screen;
  • The vectorial frequency converter allows to manage it with high precision.
  • The handling parts to move the bottle in the machine are reduced to the minimum, so as the change-over downtimes.
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The PRESS-ON CAPPER is a linear machine used for caps applied on the bottle by pressure. It includes:

  • Cap hopper
  • Canal chute
  • Placing system of cap on the neck
  • Device to snap the cap on the neck
  • Specific systems to sterilize the caps in order to avoid the contact of contaminating agents present on the cap with the bottle neck


The bottle takes the cap directly from the canal chute. The snapping of the cap on the bottle neck is carried out through the pressure developed by a belt conveyor, provided with a system to adjust the force in order not to stress the bottle.

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Palletizier has the following main features:

  • 100% machine designed expressely for 5 gallon palletizing (heavy duty application)
  • Very simple and reliable machine, which doesn't need brushless motors or any other sofisticated mechanism to work
  • Bottle transfer system from the conveyor to the rack pocket doesn't grip the bottle by the neck. This avoids the manipulation of the cap, which is a very sensitive area
  • The machine is managed by a Touch screen control panel
  • The machine is provided with overload safety device
  • The price, compared to robots, is very competitive
  • Very flexible bottles introduction on the racks, based on a slide + pusher: this ensures much more tolerance than conventional neck gripping mechanism

 

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TECNA ISO-C FM is the isobaric, volumetric filling system with electropenumatically controlled valve suitable for filling of carbonated or non carbonated drinks in cans. The cans are placed under the filling valve without the traditional lifting system: it is the filling valve which, by lowering, guarantees a good sealing between can and filling valve. After the flushing phase with gas and next pressurization, the product valve opens and the product flows along the can wall, thus allowing gentle and no foam filling. Once the quantity of product, set in the recipe, has been delivered, the magnetic flowmeter closes the valve. After a settling phase, the decompression valve reduces the pressure in the head space of the can (even in multiple stages) and, after lifting the valve, the container can be transferred to the seamer. The versatile filling system allows, thanks to the recipes memorable in the PLC, great flexibility in the changes due to different products or different levels of carbonation. The format changes are quick with reduced intervention times for different can formats and no part of the filling valve to be replaced in the case of different lids (200,202 or 206).

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TECNA G-V-RS is the electro-pneumatic filling solution, by gravity, suitable for filling still water or ready to drink in glass bottles. A quick selection, by operator touch screen, also allows different filling recipes. The filling valve open and the product can flow, thanks also to a swirl system, along the bottle wall, thus allowing a gentle filling. During filling, thanks to the special solution with separate return, the air in the bottle is conveyed into an independent manifold and not into the product tank. When the level in the bottle reaches the vent tube the filling stops and the valve closes. The filling of still drinks is possible but must be verified on the basis of the characteristics of the product and the needed shelf life. The extremely versatile filling system allows, thanks to the recipes memorized in the PLC, great ease in changes due to different products. The format changes are quick and with reduced intervention times: for a greater flexibility the automatic system for the centralized adjustment of the fill level, can also be provided.

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STELLA RS-P is the gravity filling system suitable for still beverages in PET bottles. The bottle handling system, by neckhandling, allows reduced intervention times for the change between the different bottle sizes. The filling valve, mechanical and double tube, has separated air return reducing to the maximum the possibility of contamination of the product in the tank. The possibility to have the top cover, equipped with high efficiency filters, allows to keep the filling area separate from the external environment. The fill level is obtained thanks to apropriate spacers.

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Zilli & Bellini linear gravity fillers are suitable to fill liquid products into empty or already pre-filled containers.

PRODUCTS

  • brine
  • gravy
  • syrup
  • vinegar

 

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TECNA ISO-V is the electro-pneumatic filling solution suitable for filling carbonated drinks in glass bottles. A quick selection of the filling recipes, by operator touch screen, also allows different steps of pre-evacuation phases. After bottle pressurization the filling valve will open and the product can flow, thanks also to a swirl system, along the bottle wall, thus allowing a gentle and no foam filling.
The inflowing product displaces the gas in the bottle, which returnes to the filling tank through the vent tube and when the level in the bottle comes to close the vent tube, the filling stops and the filling valve closes again.
The self level correction system, if present, optimizes the accuracy of the fill level in case of narrow bottle neck. After a settling phase, the snifting valve reduces the pressure in the bottle neck (can be also multiple stages) and than the container leaves the filling machine. The extremely versatile filling system allows, thanks to the recipes memorized in the PLC, great ease in changes due to different products or different carbonation levels. The format changes are quick and with reduced intervention times: for a greater flexibility the automatic system for the centralized adjustment of the fill level, can also be provided.

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