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:
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.
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.
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.
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.
已获得 FDA 批准的 Modulbloc 技术是适用于低速/中速灌装生产线的智能解决方案。它适用于高酸和低酸饮料,每小时可以生产高达 18,000 瓶的 500 ml 瓶装饮料,并且可以连续生产 165 小时而无需在中间插入 SOP 周期。
Whitebloc 专门为乳品行业设计,它是将产品无菌灌装到 HDPE 和 PET 容器中的理想解决方案。Whitebloc 使用基于过氧化氢 (H2O2) 的杀菌技术来保证奶基饮料和敏感饮料的保质期。
ECOSpin2 Zero 是第七代基于 GEA PAA 的无菌灌装机,这是一个非常紧凑的系统,包含封闭在微生物隔离装置中的旋转式杀菌器、灌装机和封口机。ECOSpin2 Zero 已获得 FDA 认证,配有所有必要的加工装置,可以生产无菌水和 PAA 溶液,并且可以过滤所有工艺液体。
GEA Aseptic Smart Doser