GEA ECOSpin2 Zero 无菌灌装系统

ECOSpin2 Zero 是创新的下一代 GEA 过氧乙酸基无菌灌装机。它同时适用于高酸 (HA) 和低酸 (LA) 塑料瓶饮料，并且可以连续生产 210 小时，无需在中间插入 SOP 周期。

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GEA ECOSpin2 Zero is an FDA-validated technology

ECOSpin2 Zero 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，重点是要节省空间、水和能源。ECOSpin2 Zero 这项技术已获得 FDA 的认证。

零排放

ECOSpin2 Zero 减少了关键的无菌区，零过氧化物排放，并且实现了有史以来最低的过氧乙酸 (PAA)、水和能量消耗，并且满足了可持续发展的市场需求。从操作和投资角度来看，具备这些特色的 ECOSpin2 Zero 成为选择 PAA 无菌灌装技术时的最佳之选。

ECOSpin2 Zero 仅使用一种 PAA 基溶液对环境和包装材料进行杀菌。另外，只需控制以下五个参数，即可达到稳定、可靠的杀菌效果：压力、温度、浓度、流速和接触时间。

使用无堵塞的穿过性喷嘴（全椎体或叶片形状）对各种 PET 瓶进行内部杀菌，包括带把手的瓶子。合并的机械和化学作用可有效地解决“冷点”污染，并符合最苛求的生产线验证方案。每个喷嘴的效用通过“智能传感器”自动检查，以确保每个瓶均经过正确杀菌。

外部瓶杀菌处理是 GEA 的独特特点，它设计为可适应品种繁多的瓶子形状，以避免微生物进入灌装区。这样可确保 GEA 生产线在无菌环境中连续运转，无需在中间插入环境杀菌周期，从而使生产时间实现最大化。

瓶子经过杀菌后，只需使用室温无菌水进行冲洗即可保证过氧化物残留量低于 0.5 ppm（符合 FDA 法规）。

Resource-efficient solution

GEA's PAA-based technology has undergone an external audit according to criteria defined by TÜV Rheinland, a world leader in testing services.

Two of the innovations introduced have earned the “Add Better” mark. The 'Add Better' mark promotes GEA's sustainable solutions, which meet the stringent requirements of ISO 14021 and offer significantly greater resource efficiency than previous solutions.

Efficient nozzle design for maximum water savings

The new water rinsing unit in PAA based machinery received the GEA Add Better label. It features a reduced water consumption thanks to a new nozzle design.

When installed on new machinery (GEA Aseptic Filling Bloc ECOSpin2 Zero and GEA Modulbloc) the system allows a water saving of up to 91%. The comparison refers to its predecessor models. The new water rinsing unit was released in 2014.

In addition, the system is suitable for service upgrades of the installed base (available from 2018), achieving a water saving of up to 83%.

Heading towards zero water waste with second rinsing water recovery system

GEA PAA-based machinery can be equipped with an advanced water recovery system that enables the reuse of up to 86% of the water used in the second rinse, reducing overall water consumption by up to 50%.

This significant improvement in sustainability and cost efficiency has received the GEA Add Better label and supports GEA’s Net Zero Mission 26.

The system is protected by a patent granted in 2025.

优势

瓶进料灵活：从卸垛机到集成吹灌系统
可靠的瓶杀菌过程得力于快速、高效率的喷雾系统
低 PAA 消耗：浓度和温度恢复后，可在闭环中重复使用溶液
无阀杀菌器设计：无电气部件、更易于维护、更少的磨损
非穿过性冲洗喷嘴使用脉冲喷射模式，可实现最少耗水量
减少了占地面积：一个专用辅助模块提供无菌水、PAA 溶液、清洗剂，以及氮、空气和蒸汽的无菌过滤

性能

ECOSpin2 Zero 适用于高酸和低酸饮料，每小时可以生产高达 72,000 瓶的 500 毫升瓶装饮料，可以连续生产 210 小时，生产期间无需中间插入 SOP 周期。瓶内部杀菌处理可保证萎缩芽孢杆菌最高降低 6 个对数级。

Cap sterilization

Sterilcap IM, the integrated cap sterilizer, treats one-piece caps by immersing them via spiral routing in a basin full of PAA solution. They are then rinsed with a sterile water spray.

The mechanical design features a jam-free spiral channel in which the caps are driven by a PAA solution flow. The same microbiological sterilization target for the bottles is also achieved for the internal and external surfaces of closures.

Pre-sterilized cap sterilization

Pre-sterilized flat/sports cap handling is also available for HA productions. A bag treatment tunnel is used for gamma-ray, pre-irradiated bags of caps that are loaded into the machine and externally sterilized with a PAA spray. After the external sterilization, the bags are opened and fed to the capper in a sterile environment.

For LA products, a dedicated rotary H2O2-based Sterilibag system handles bags of pre-sterilized caps (FDA approved). Gamma-ray irradiated bags of caps are externally sterilized, opened and fed to the capper in a controlled environment.