Aseptic filling modules

Benefits:

• Automatic dummy bottle insertion and extraction for closed-loop clean-in-place (CIP) and sterilize-in-place (SIP) procedures
• Redundant HEPA filters supply sterile air to the microbiological isolator to offer the same protection level required by FDA regulations
• On-board tank design reduces product loss during changeover
• Bottle format changeover can be done without losing sterility 

Aseptic filling of still products

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.

FX range of electronic filling valves

Fillstar CX

The Fillstar CX aseptic volumetric electronic filling module can fill both still and carbonated drinks in aseptic conditions, including clear products and those containing pulps and fibers.The Fillstar CX is optimized to aseptically fill carbonated liquids (with contact between the bottle and filling nozzle), as well as the aseptic filling of still liquids (with no nozzle-to-bottle contact).

Rapid changeovers

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.

Aseptic cold dosing for fruit and 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.

Benefits:

• The aseptic Piston Doser Fillstar PX handles the whole bottling process, eliminating the need for downstream heat treatment or beverage overheating.
• Energy costs are dramatically reduced.
• Extreme flexibility when preparing products containing fruit, hard or soft particles, pulps and fibers. 

Magnetic filling valves

The GEA aseptic filling valve portfolio now benefits from the newly designed solution fit for filling a large variety of still sensitive beverages, including pulps and particles. It features magnetic actuators thus bringing flexibility and accuracy to a higher level and enhances versatility when filling high level carbonated sensitive beverages.