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The GEA aseptic filling modules are enclosed in a microbiological isolator in which the environment is cleaned and sterilized prior to production. The sterility is maintained during production with overpressure sterile air that’s supplied by an air management system equipped with double HEPA filters.
They can all be paired with GEA PAA-based or H2O2-based aseptic sterilization systems.
Our latest generation of aseptic filling modules introduces three key innovations designed to maximize hygiene, efficiency and reliability.
A design that delivers hygiene
Our new aseptic line design combines sleek aesthetics with advanced hygienic engineering. Smoother internal and external surfaces allow for easier manual cleaning, and wider doors and improved accessibility simplify maintenance. Following EHEDG guidelines, the new design guarantees a safer, cleaner product environment because, in aseptic filling, hygiene is performance.
Boosting up time with smart control
Our new 24" AI-assisted HMI panel, now directly integrated into the aseptic filler, revolutionizes troubleshooting. With a wider, more intuitive display and smart alarm management, it identifies the root cause of issues and suggests prioritized solutions based on real-world data from global installations. This means faster interventions, reduced downtime, and smarter operations.
Always visible, always ahead
The new upper display, clearly visible from up to 20 meters away, keeps operators constantly informed, even when they're not near the machine. With real-time color-coded status, area-specific alarms, and proactive alerts for upcoming tasks, it helps prevent unplanned stops and boosts overall line efficiency. It’s smart visibility that keeps your production flowing.
Benefits of GEA aseptic filling modules:
- 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
Volumetric electronic filling modules
The range of aseptic volumetric electronic filling modules, supplied with magnetic flow meters, is suitable for a wide range of still and carbonated products.
Fillstar FX
The Fillstar FX series is suitable for high or low acid, clear or viscous products, and those with pulps, fibers and/or pieces up to 6 x 6 x 6 mm in size.
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.
Fillstar CX
The Fillstar CX filling module can fill both still and carbonated drinks in aseptic conditions, including clear products and those containing pulps and fibers. It 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).
The Fillstar CX can 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.
GEA’s Aseptic Dual Fill System
The GEA Aseptic Dual Filling System opens the door to a new generation of premium beverages containing pulp, fiber, fruit chunks, cereals and other large particles. Designed for sensitive, high-value products, it enables precise handling of solids and liquids via two independent aseptic streams, preserving natural freshness and delivering outstanding product quality. Whether you're bottling aloe vera pieces or mandarin sacs, the GEA Aseptic Dual Fill ensures each component is treated with the care it deserves.
Aseptic-smart-doser
At the heart of the system is the GEA Aseptic Smart Doser. It uses a magnetic actuated piston system to first dose the solid particles, thereby minimizing product damage and optimizing dosing precision. After the particles are dosed, an aseptic electronic volumetric filler completes the process by dosing the remaining liquid, whether still or carbonated. This provides infinite possibilities for creating unique, sensitive beverages.
The GEA Aseptic Smart Piston Doser gently and accurately doses solid particles up to 10x10x10 mm, even in small volumes – ideal for today's “food in a bottle” trends.
Dedicated thermal treatments
The GEA Aseptic Dual Filling System requires a two-stream process line: one dedicated to the thermal treatment of the pieces and one for the clear liquid that preserves their organoleptic and nutritional properties.
Thanks to extensive experience with this type of application, GEA can offer an effective solution by combining the GEA Smart Doser with GEA thermal treatment technologies to optimize both solid particle dosing accuracy and integrity.
Benefits:
- The GEA Aseptic Piston Doser 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.
Benefits
- Reduced maintenance solution with no dynamic sealing (such as bellows or membranes) to separate the aseptic zone from the external environment
- High reliability valve sealing solution without additional gaskets and no off-flavor retention
- Easy and fast change over with simple replacement of the terminal nozzle allows to switch between high level carbonated products to still products clear or including fibers
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无菌灌装机 Whitebloc
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。
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GEA 提供了适用于任何敏感产品的一系列无菌灌装机
敏感饮料的灌装对于卫生和安全性要求很高。GEA 无菌灌装模块通过特别关注环境控制并在速度、准确性和灵活性方面优化性能来管理产品的任何可能风险。PET 和 HDPE 瓶均可使用所有 GEA 灌装机进行灌装。
灌装模块被封装在一个微生物隔离装置中，其中的环境在开始生产前经过清洁和杀菌处理。生产过程中使用配有双 HEPA 过滤器的空气管理系统提供的超压无菌空气来保持无菌状态。
GEA 无菌灌装模块系列包括：
- Fillstar FX
- Fillstar CX
- Fillstar PX 活塞分量
- 电磁灌装阀
它们 都可以与基于 GEA PAA 或基于 H₂O₂ 的无菌杀菌系统配合使用。
优势：
- 自动空瓶插入和抽出，用于闭环原位清洗 (CIP) 和原位杀菌 (SIP) 程序
- 冗余 HEPA 过滤器向微生物隔离装置提供无菌空气，以提供 FDA 法规要求的相同保护水平
- 机载罐设计减少了切换期间的产品损失
- 可以进行瓶子规格切换而不会失去无菌性
Fillstar FX
Fillstar FX 无菌容积电子灌装模块系列，配有电磁流量计，适用于多种不起泡产品。
Fillstar FX 无菌模块的详细信息
无菌灌装不起泡产品
将产品从位于灌装转盘顶部的无菌缓冲罐重力输送到灌装阀。每个灌装阀均配有电磁流量计，用于根据容器尺寸调节液体量。双速设计（在灌装周期开始和结束时使用慢速模式）可灌装对泡沫敏感的产品而不会产生不必要的湍流。
产品灌装回路经过蒸汽灭菌； 由于灌装过程中喷嘴与瓶子之间没有接触，因此，该系统可以实现安全可靠的无菌生产。
FX 电子灌装阀门系列
- FX 灌装阀门：特别设计用于不起泡、透明产品
- FX P EVO 灌装阀门：适用于不起泡产品，带不带果肉和纤维均可（最大尺寸 3 毫米 x 20 毫米）
- FX C EVO 灌装阀门：适用于不起泡产品，透明或带有果肉、纤维和最大尺寸 6 毫米 x 6 毫米 x 6 毫米的小块
Fillstar CX
Fillstar CX 无菌容积电子灌装模块可在无菌环境下灌装不起泡和碳酸饮料，包括透明产品和含有果肉和纤维的产品。Fillstar CX 经过优化，可无菌灌装碳酸液体（瓶子与灌装喷嘴之间有接触），以及无菌灌装不起泡液体（喷嘴与瓶子没有接触）。快速切换
Fillstar CX 能够从“无接触”灌装过程切换为“接触”灌装过程，反之亦然，无需关闭系统进行机械调整。有效消除了通常需要 3 个小时以上的切换时间。
预先确定与特定产品相关的灌装参数，并且可以使用机器的控制系统进行调用，而不会中断无菌灌装过程。
2Fillstar PX
使用包含两个不同模块的系统对含有大颗粒的饮料进行无菌灌装：无菌活塞分量 Fillstar PX 设备可以与 Fillstar FX 或 Fillstar Cx 结合使用，以灵活地生产含有大颗粒的不起泡和碳酸饮料。
Fillstar PX 无菌活塞分量是无菌双灌装系统的一部分，适用于含有大块水果或谷物的敏感饮料
适用于水果和谷物的无菌冷配量
市场上大多数含有固体颗粒的饮料都使用热灌装技术灌装到瓶子或易拉罐中，或者灌装后在高压灭菌器中进行杀菌。但是，这带来了许多问题：热处理（需要充分处理以达到固体块的核心）可能会影响饮料的味道和营养特性。因此，容器必须足够坚固以承受过程中涉及的温度和压力而不会变形。此外，整个过程的能源效率极低。
GEA 开发的无菌双灌装系统可用于在冷灌装环境中灌装轻质塑料瓶，并实现最低能耗且达到所需的配量精度。
无菌双灌装系统具有两个独立的灌装模块，均位于同一微生物隔离装置内；第一个分配固体颗粒的量，第二个通过添加透明液体产品来完成无菌灌装过程。
无菌活塞分量 Fillstar PX 设备与 Fillstar FX 或 Fillstar CX 灌装模块结合在一起，通过添加透明液体产品来完成加工。
双灌装系统需要两个串流工艺生产线：一个专门用于热处理小块，另一个用于透明液体，以保留其感官和营养特性。
利用这类应用的丰富经验，GEA 可以将无菌活塞分量 Fillstar PX 设备与 GEA 热处理技术相结合，从而优化固体颗粒配量的准确性和完整性，从而提供有效的解决方案。
优势：
- 无菌活塞分量 Fillstar PX 设备可处理整个装瓶过程，无需进行下游热处理或消除了饮料过热情况。
- 大大降低了能源成本。
- 在制备含有水果、硬或软颗粒、果肉和纤维的产品时具有极大的灵活性。
电磁灌装阀
GEA 无菌灌装阀产品组合现在得益于新设计的解决方案，适用于灌装多种仍然敏感的饮料，包括果肉和颗粒。它配有磁性执行器，因此可将灵活性和准确性提高到更高水平，并且在灌装高含量碳酸敏感饮料时增强了多功能性。优势
- 减少维护工作的解决方案，无需动态密封（如波纹管或膜）将无菌区与外部环境隔开
- 高可靠性的阀门密封解决方案，无需额外垫圈且无异味残留
- 只需更换末端喷嘴即可轻松快速地进行转换，允许在高含量碳酸产品之间切换到透明或含有纤维的不起泡产品
