Filling Lines – Filling modules
GEA offers a range of volumetric electronic filling modules that meet stringent sterile environment requirements. A wide variety of drinks can be filled, including high and low acid, still and carbonated beverages, with and without pulps, fibers or pieces.
GEA offers a range of aseptic fillers for any sensitive product
The filling of sensitive beverages demands high levels of hygiene and safety. GEA aseptic filling modules manage any possible risk to the product by paying special attention to environmental control and optimizing performance in terms of speed, accuracy and flexibility. Both PET and HDPE bottles can be filled with all GEA fillers.
The filling modules are enclosed in a microbiological isolator in which the environment is cleaned and sterilized prior to production. The sterility is maintained during production with overpressure sterile air that’s supplied by an air management system equipped with double HEPA filters.
The GEA range of aseptic filling modules includes:
They can all be paired with GEA PAA-based or H2O2-based aseptic sterilization systems.
Detail of the Fillstar FX aseptic module
Product is gravity fed to the filling valves from a sterile buffer tank located on top of the filling carousel. Each filling valve is equipped with a magnetic flow meter that regulates the quantity of liquid according to the container size. A dual-speed design (slow speed mode is used at the beginning and end of the filling cycle) enables foam-sensitive products to be filled without unwanted turbulence.
The product filling circuits are steam sterilized; the system — with no contact between the nozzle and the bottle during filling — allows for safe and reliable aseptic production.
The Fillstar CX has the ability to switch from a “no-contact” filling process to a “contact” one — and vice versa — without the need to shut down the system for mechanical adjustment. Changeover times that typically take more than 3 hours are effectively eliminated.
The filling parameters related to the specific product are predetermined and can be recalled using the machine’s control system without interrupting the sterile bottling process.2
The Fillstar PX aseptic piston doser is part of the Aseptic Dual Filling System, suitable for sensitive beverages containing large pieces of fruit or cereals
Most drinks on the market that contain solid particles are filled into bottles or cans using a hot fill technique or are sterilized, after filling, in an autoclave. However, this presents a number of problems: the heat treatment — which requires to be adequate to reach the core of the solid pieces — can affect the taste and the nutritional properties of the drink. As such, containers must be sufficiently robust to withstand the temperatures and pressures involved in the process without distortion. In addition, the whole process is extremely energy inefficient.
The aseptic Dual Filling System developed by GEA can be used to fill lightweight plastic bottles, in a cold-fill environment, with minimal energy consumption and the required level of dosing accuracy.
The aseptic Dual Filling System has two separate filling modules, both located inside the same microbiological isolator; the first doses the solid particles and the second completes the aseptic filling process by adding the clear liquid product.
The aseptic piston doser Fillstar PX is coupled with the Fillstar FX or Fillstar CX filling module that complete the process by adding the clear liquid product.
The Dual Filling System requires a two-stream process line: one dedicated to the thermal treatment of the pieces and one for the clear liquid that preserves their organoleptic and nutritional properties.
Thanks to an extensive experience with this type of application, GEA can offer an effective solution by combining the aseptic piston doser Fillstar PX with GEA thermal treatment technologies to optimize both solid particle dosing accuracy and integrity.
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.
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.
Ensuring food safety at the best in class TCO, the GEA DBF system make the advantages of preform decontamination and blow-fill integrated technology available to a wider range of sensitive beverages, with options for shelf stable to ESL based on the distribution chain.
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.
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GEA is one of the world’s largest systems suppliers for the food, beverage and pharmaceutical sectors. Our portfolio includes machinery and plants as well as advanced process technology, components and comprehensive services. Used across diverse industries, they enhance the sustainability and efficiency of production processes globally.
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