Container decontamination ESL Filling bloc Whitebloc

Special requirements must be addressed when decontaminating bottles for milk-based drinks and beverages as the required shelf life up to 60 days is to be achieved. Whitebloc is the low container decontamination solution that meets those requirements.

Whitebloc is a new technology concept, specifically designed for the dairy industry that is ideal for HDPE and PET container handling and, combined with Fillstar DX filler, is available for all ESL product applications distributed with the cold chain. Whitebloc allows users to choose the right decontamination target for every kind of product, high acid or low acid, according to the specific shelf life required. Whitebloc uses a completely dry technology based on H2O2 treatment.

H2O2 based ESL filling bloc for sensitive products filling into PET or HDPE bottles distributed in cold chain

Detail of H2O2 based treatment for PET or HDPE containers
Detail of H2O2 based treatment for PET or HDPE containers

The process is carried out in two different phases. During the dosing phase, the bottles enter the first carrousel where a system of nozzles doses a spray of H2O2 solution. All critical points are controlled automatically to ensure the maximum decontamination efficacy (up to 5 Log reduction with A.brasiliensis at the end of treatment).
A Smart SensorTM system checks the pressure and flow rate of H2O2 at every nozzle in real time making the system easy to control, reliable and preventing stoppages caused by clogging.
The activating phase takes place on the second carrousel. Here the bottles are flushed by hot sterile air that activates the H2O2, purges out peroxides and achieves a final peroxide level of less than 0.5 ppm.
The entire system is simple, has no moving parts or valves on the two treatment carrousels, and is very effective. No water is required. Whitebloc has a very compact design with all the ancillaries on board to achieve a very small footprint.
The NeckFlex neck handling system is suitable for both PET or HDPE containers and can treat a huge range of bottles, from ’single serve’ 200ml bottles to 1 US gallon format, at low, medium and high speed. 

The Clean Box: the key to ESL technology

The Clean box is a physical of the ultraclean environment. To prevent bottles being re-contaminated after the H2O2 treatment, the filler/capper zone is surrounded by a sterile air flow (from HEPA filter).  This sterile air carries an ambient overpressure of 10 Pa.
All surfaces in the Clean Box are accessible and very easy to clean. 

Sterilcap VHP L: dry H2O2 technology for cap decontamination

Sterilcap VHP L: dry H2O2 technology for cap sterilization
Sterilcap VHP L: dry H2O2 technology for cap sterilization

Sterilcap VHP L is a totally dry system designed to handle flat or sport caps. Its exceptional flexibility means it can handle a wide range of decontamination target levels - up to 5 Log on A.brasiliensis -  to meet the required shelf life.
Through the preheating phase the caps are subjected to the ideal temperature profile avoiding any condensation risk: this allows a very low total peroxides residual (<0.05ppm).
Despite a strong and effective decontamination, the VHP flow has a gentle treatment on the caps that doesn’t remove the slipping agent: the caps are pushed forward using only the vapor flow and gravity.

Sterilfoil VHP L: dry H2O2 technology for foil decontamination

Detail of Sterilfoil VHP L

Through a combined action of H2O2 condensing and VHP treatment (C-VHP), the system achieves a maximum decontamination efficacy (up to 6 log on B.atrophaeus).  The simple mechanical construction provides customers with a safe and hygienic closure system for HDPE containers.
A specific compact sterilization chute allows simultaneous internal and external decontamination. Foils are pushed forward in a pressurized VHP flow through rails shaped to change the contact points during sterilization. The sterilization chute is electrically heated on both sides to prevent H2O2 condensation, avoid foil jams and prevent damage which would later result in poor foil turret unit performance.