Aseptic Blow Fill System ABF

Suitable for both high and low acid operations, the ABF 1.2 combines an aseptic blow molding module with aseptic filler and capper modules, and features a hydrogen peroxide-based sterilization technology for preforms and caps.

With the ABF technology, LA and HA aseptic beverages with different shelf lives can be filled on the same system

The ABF system reduces the use of chemicals and doesn't need any water in production

Detail of the ABF preform sterilization treatment

The ABF 1.2 is the latest evolution of the world’s first rotary aseptic blow molding machine with an integrated aseptic filler and capper. It’s designed to sterilize the preform with hydrogen peroxide when leaving the oven, then blow the preforms with sterile air in an aseptic environment and maintain this sterility throughout the filling and capping process.

The concept

Preform sterilization treatment with Hydrogen Peroxide

The preforms are sterilized as soon as they leave the oven, where they are heated to optimize their thermal profiling, 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 the sterile zone – 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 a pre-sterilized 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 1.2 system is specifically designed for aseptic applications and completely enclosed within the microbiological isolator.

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Benefits:

Preform sterilization treatment with Hydrogen Peroxide

Full automated sterilization of the blowing, filling and capping modules, which is effective, repeatable and automated, needing no operator intervention
Low chemical and no water consumption during production
Minimum VHP residuals in the container
Limited downtime (3 hour cleaning and sterilization cycles) for product changeovers
Microbiological validation according to specific protocols for sensitive beverage industry
FDA PoC approved

Performance

The versatile ABF 1.2 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. Production speed is up to 48.000 single-serve bottles per hour can be achieved with a wide range of formats (up to 2.5 liters).

H2O2 technology for cap and foil sterilization

Sterilcap VHP cap sterilizer

Similar to the preform sterilization system, the ABF 1.2 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 1.2 solution offers maximum flexibility when treating aluminum foil closures with Sterilfoil VHP L technology.