GEA Unibloc Flex

More and more beverages today are being bottled and sold in aluminum – from sparkling water to craft beer, energy drinks, hard seltzer and cold brew coffee. But one increasingly popular category of beverages has been left out of the mix thus far: highly sensitive beverages such milk-based and plant-based drinks. These are in demand due to their nutritional content, but also unsuitable for traditional processing technologies for aluminium or tin cans, such as hot filling or filling with preservatives.

GEA has solved this problem with a new aseptic filling line that accommodates aluminum, glass, PET and HDPE bottles: the Unibloc Flex. While originally developed to unlock aseptic filling for aluminum bottles, Unibloc Flex has evolved into a highly flexible aseptic platform. By accommodating aluminum, glass, PET and HDPE containers on the same system, it allows beverage producers to diversify their packaging portfolio without relying on different filling technologies.

Pioneering aseptic filling for aluminum and glass

The GEA Unibloc Flex is the world’s first line system for filling aluminum bottles with aseptic processing technology. As the first rotary aseptic solution for both aluminum and glass bottles, it expands packaging possibilities for sensitive beverages while maintaining the highest aseptic standards. The GEA Unibloc Flex can process extremely sensitive liquid products – including milk-based and plant-based beverages – either still or carbonated, with or without particles. A simple, robust solution for reliable container and closure sterility in all environments, the GEA Unibloc Flex makes it easy for sensitive beverage producers wanting to add aluminum bottles to their portfolio. It requires just a simple adjustment when changing from one bottle shape or format to another, needs minimal maintenance and, given its compact layout, can be managed by a single operator.

GEA Unibloc Flex – Taking aseptic beverages to the next level 

• Proven aseptic filling technology (peracetic acid and vaporized hydrogen peroxide) for container sterilization achieves safe, premium products with very long shelf-life
• Suitable for both high-acid and low-acid beverages
• Cutting-edge technology for aluminum closures sterilization and handling
• Aluminum bottles with threaded cap for re-closability and portability
• Accommodates aluminum, glass, PET and HDPE bottles
• Minimum maintenance, compact layout, single operator
• Saves energy compared to conventional retort processing 

Aluminum on the move

Why is aluminum trending today as a bottling material? For starters, its elegant appearance lends beverages a more premium look and feel. But the list of advantages is long. It provides an excellent barrier against light, air and bacteria and can’t be beat for preserving the taste, color, odor and feel of beverages – while also ensuring their safety and nutritional integrity. Made with a single material, aluminum bottles are both 100% recyclable and, in contrast to multi-material packaging, easily recyclable thanks to established collection systems. Aluminum bottles can be printed directly, which means no additional plastic labeling is required. And recent advances mean that less aluminum is needed to make each bottle, which translates into lower raw material and energy usage.

The GEA advantage 

For decades, GEA has proven the high sterilization efficiency and reliability of its aseptic technology for every step of sensitive beverage bottling – and boasts more than 15 years of experience in FDA-approved projects and numerous packaging sterilization tests on aluminum bottles. GEA worked for more than a year together with aluminum bottle and closure suppliers to develop the groundbreaking GEA Unibloc Flex, a solution originally designed for aseptic aluminum bottling and now capable of accommodating aluminum, glass, PET and HDPE containers on a single aseptic platform.