Filling Lines – Aseptic

GEA Modulbloc Aseptic Filling System

Modulbloc peracetic acid (PAA)-based sterilization technology is a smart solution for low/medium-speed filling of plastic bottles. It allows continuous production of both high acid (HA) and low acid (LA) beverages for up to 165 hours.

Comprising four carrousels – sterilizer, rinser, filler and capper – enclosed in a microbiological isolator, the FDA-validated Modulbloc provides a robust, proven and reliable aseptic technology for low to medium speed filling applications.

Compact design

Modulbloc incorporates a sterilizer carrousel, a rinser carrousel, a filler carrousel and a capper carrousel on a single base frame. The ancillaries, aseptic process units and the cap sterilizing machine are located on top of the machine. Its compact design makes the Modulbloc the right choice even when space is limited, or for relatively small beverage producers that require the latest in aseptic filling technology.

Bottle sterilization and rinsing

PET bottles and closures, as well as the microbiological isolator environment, are spray treated with a peracetic acid (PAA) solution at a given concentration, temperature and pressure. Once the bottles have been sterilized, both externally and internally, with a full-cone, no clogging penetrating nozzle system, a sterile water rinse ensures a final residual peroxide level of less than 0.5 ppm (as per FDA regulations).

The efficiency of each nozzle is automatically checked by a ’Smart Sensor’ that ensures proper sterilization of each bottle. Both rinser and sterilizer have been specifically designed to minimize the number of wear and tear parts for easy maintenance.


  • Bottle feed flexibility: from depalletizer to integrated blow-fill system
  • Reliable bottle sterilization process thanks to a rapid high-efficiency spraying system
  • Reduced rinsing time and water consumption (< 1 m3/hour)
  • Total residual peroxide of less than 0,5 ppm in the final product
  • Compact design thanks to the positioning of the cleaning, cap sterilization and sterile fluid filtration units on top of the machine


Various Modulbloc configurations enable machine speeds from 1,250 b/h (pilot plant) to 22,000 b/h. It’s suitable for both HA and LA beverages and allows a line availability of 165 hours without the need for intermediate SOP cycles during production.

Cap sterilization

Sterilcap L is a low-speed cap sterilization unit that’s integrated into the Modulbloc: it handles flat caps and chemically sterilizable sport caps. Closures are spray treated with a PAA-based solution and briefly rinsed with sterile water. After the sterilization treatment, the caps are gravity fed to the capper.

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