The concept
The preforms are sterilized as soon as they leave the oven, where they are heated to optimize their thermal profiling and to minimize energy consumption and the use of the sterilizing agent. The internal and external surfaces of the preforms are treated with vaporized hydrogen peroxide (VHP) using a robust, controlled and condensation-free process to minimize residue values and achieve a 6 log decontamination performance.
After the sterilization process, the preforms enter a pre-sterilized microbiological isolator – where the aseptic blowing wheel is located – and are blown with sterile air supplied through a filtered circuit that includes a dedicated VHP sterilization system.
The fresh-blown sterile bottles are transferred by the neck from the aseptic blower to the aseptic filling module without leaving the sterile zone. The aseptic filler is enclosed in the same microbiological isolator, in which sterility is maintained during production with an overpressure of class 100 sterile air. As well as the filler module, the capper module in the ABF 2.0 system is specifically designed for aseptic applications and completely enclosed within the microbiological isolator.
Benefit:
- Full automated sterilization of the blowing, filling and capping modules, resulting in an effective, repeatable and automated process, needing no operator intervention
- Low chemical and no water consumption during production
- Minimum H2O2 residuals in the container (<0.5 ppm)
- Limited downtime (3 hours cleaning and sterilization cycles) for product changeovers
- Microbiological validation according to specific protocols for sensitive beverage industry
- PoC approved, being based on ABF 1.2 FDA approved architecture
Aseptic blower
The GEA Aseptic Blow Molder is an integral part of the ABF 2.0 system. It is an aseptic blower that produces sterilized bottles by aseptically blowing preforms being previously sterilized with hydrogen peroxide vapor (VHP).
Specifically designed with aseptic functionality in mind, the GEA Aseptic Blow Molder is placed in the same sterile zone where the filling and capping processes are performed. It has been designed to be completely sterilizable.
Blow molder aseptic design
The environmental sterilization process is completely automated requiring no manual intervention from the operator, therefore greatly decreasing any risk of system recontamination.
The aseptic blowing process
Sterile stretching rod (patended)
Resource-efficient solution
The air recovery system in aseptic blower is one of our most resource-efficient solutions and carries the Add Better label.
The Add Better label relates to the air recovery system in GEA ABF 2.0 which reduces the amount of energy consumption for the compressed air needed for blowing process and cap sterilization up to 31% when compared to its predecessor model.
The air recovery system was released in 2024.
Performance
The versatile ABF 2.0 aseptic production system can process extremely sensitive, high and low acid, still or carbonated beverages, with or without particles. It can deliver a 6 log reduction for both cap and preform decontamination in a single sterilization phase and offers continuous aseptic production runs of 165 hours without stoppages or intermediate cleaning.
H2O2 technology for cap and foil sterilization
Similar to the preform sterilization system, the ABF 2.0 cap sterilization module – Sterilcap VHP R – also uses VHP at the correct concentration and temperature. The specially adapted design, including a rotary cap buffer that guarantees the necessary redundancy required by the blow-fill technology, ensures that all the cap surfaces are exposed, preventing any ‘shadow’ areas and avoiding the risk of cap deformation.
The cap sterilization module can be used to treat both sport and flat caps. Offering rapid changeovers without any mechanical intervention and without losing sterility, the ABF 2.0 solution offers maximum flexibility when treating aluminum foil closures with Sterilfoil VHP L technology.
Downloads
関連製品
無菌充填ブロック Modulbloc
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無菌充填ブロック Whitebloc
乳業業界向けに特別に設計されている Whitebloc は、HDPE 容器と PET 容器での製品の無菌ボトリングに最適なソリューションです。Whitebloc は、過酸化水素 (H2O2) ベースの滅菌技術を使用して、ミルクベースのドリンクと敏感な飲料の賞味期限を保ちます。
無菌充填ブロック ECOSpin2 Zero
ECOSpin2 Zero は、GEA PAA ベースの無菌充填ブロックの第 7 世代であり、微生物アイソレータに密閉された回転式滅菌器、充填機、キャッパーで構成される非常にコンパクトなシステムです。FDA 承認の ECOSpin2 Zero は、滅菌水と 過酢酸 (PAA) 溶液を生成し、かつ、すべての処理流体をろ過するのに必要なすべての処理装置を備えています。
サービス製品
GEA Remote Support Filling
飲料充填工場に3レベルのプロフェッショナルリモートアシスタンスを提供する GEA サービスをぜひご覧ください。
GEA eShop Filling
充填用予備品を24時間365日対応のオンラインで注文できるユーザーフレンドリーなインターフェース GEA eShop Filling を発見してください。
GEA Smart Filling
GEA Smart Filling は、ウェブとモバイルアプリが完全に統合されたプラットフォームで、お客様のあらゆるサービスニーズにお応えします。
GEA AseptiCheck®
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.
GEA充填およびパッケージングライン用サービスキット
お客様のGEA充填・パッケージングラインの最適なメンテナンスに必要なすべてを注文して、信頼性と稼働時間を保証。
関連のある動画
GEA Aseptic Smart Doser
