Filling Lines – Aseptic
ECOSpin2 Zero is an innovative, next-generation version of GEA peracetic acid-based aseptic filling blocs. Suitable for both high acid (HA) and low acid (LA) beverages in plastic bottles, it allows a line availability of 216 hours without the need for intermediate SOP cycles during production.
ECOSpin2 Zero features a reduced critical aseptic zone and, with zero peroxide emissions and the lowest ever peracetic acid (PAA), water and energy consumption, meets the market demand for sustainability. These features make ECOSpin2 Zero the best choice from an operational and investment point of view when choosing PAA aseptic filling technology.
PAA based sterilization treatment
ECOSpin2 Zero uses only one PAA-based solution to sterilize both the environment and the packaging materials. Plus only five parameters have to be controlled to achieve robust and reliable sterilization: pressure, temperature, concentration, flow rate and contact time.
A clogging-free penetrating nozzle (full-cone or blade shape) is used for internal sterilization of a wide range of PET bottles, including those with handle. The combined mechanical and chemical action effectively addresses ‘Cold Spot’ contamination and complies with the most demanding line validation protocols. The efficiency of each nozzle is automatically checked by a ’Smart Sensor’ that ensures the proper sterilization of each bottle.
External bottle sterilization treatment, a distinctive feature of GEA, is designed to accommodate a vast array of bottle shapes to avoid microbiological transfer into the filling area. This ensures that GEA lines continuously operate under aseptic conditions – with no intermediate environmental sterilization cycles – maximizing the production time.
After sterilization, the bottle is briefly rinsed with sterile water at ambient temperature to guarantee a residual peroxide level of less than 0.5 ppm (as per FDA regulations).
The new water rinsing unit in PAA based machinery received the GEA Add Better label. It features a reduced water consumption thanks to a new nozzle design.
When installed on new machinery (GEA Aseptic Filling Bloc ECOSpin2 Zero and GEA Modulbloc) the system allows a water saving of up to 91%. The comparison refers to its predecessor models. The new water rinsing unit was released in 2014.
In addition, the system is suitable for service upgrades of the installed base (available from 2018), achieving a water saving of up to 83%.
ECOSpin2 Zero is suitable for HA and LA beverages; it can reach a production speed with 500 ml bottles of up to 72,000 bottles per hour, and allows a line availability of 216 hours without the need for intermediate SOP cycles during production. The internal bottle sterilization treatment guarantees a B. atrophaeus reduction of up to 6 log.
Sterilcap IM, the integrated cap sterilizer, treats one-piece caps by immersing them via spiral routing in a basin full of PAA solution. They are then rinsed with a sterile water spray. The mechanical design features a jam-free spiral channel in which the caps are driven by a PAA solution flow. The same microbiological sterilization target for the bottles is also achieved for the internal and external surfaces of closures.
Pre-sterilized flat/sports cap handling is also available for HA productions. A bag treatment tunnel is used for gamma-ray, pre-irradiated bags of caps that are loaded into the machine and externally sterilized with a PAA spray. After the external sterilization, the bags are opened and fed to the capper in a sterile environment.
For LA products, a dedicated rotary H2O2-based Sterilibag system handles bags of pre-sterilized caps (FDA approved). Gamma-ray irradiated bags of caps are externally sterilized, opened and fed to the capper in a controlled environment.
FDA-validated Modulbloc technology is a smart solution for low/medium-speed filling lines. It’s suitable for both HA and LA beverages, can reach production speeds of up to 18,000 bottles per hour on 500 ml bottles and allows a line availability of 165 hours without the need for intermediate SOP cycles during production.
Specifically designed for the dairy industry, Whitebloc is the ideal solution for the aseptic bottling of products in HDPE and PET containers. Whitebloc uses an hydrogen peroxide (H2O2)-based sterilization technology to preserve the shelf-life of milk-based drinks and sensitive beverages.
Suitable for both high and low acid operations, the ABF 2.0 combines an aseptic blow molding machine with aseptic filler and capper modules, and features a hydrogen peroxide-based sterilization technology for preforms leaving the oven and caps.
Discover GEA Service with three levels of professional remote assistance for your beverage filling plants.
Order everything you need for optimal maintenance on your GEA filling and packaging lines, guaranteeing reliability and uptime.
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Protect the operation of your aseptic beverage plant and safeguard the final quality of your product by safely controlling the risks regarding every process parameter of an aseptic filling system.
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