New Technology of Liquid Filling-Multifunctional Aseptic Production Line
Nov 30, 2021
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Since 2002, Huiyuan Juice Group has invested heavily in introducing the sterile cold filling production line of PET bottles, and the domestic sterile filling technology has gone through the process of continuous research and development, accumulation and breakthrough for nearly 20 years. Langfang Baiguan Packaging Machinery Co., Ltd. launched the GWJX series multifunctional aseptic blowing, filling and spinning production line in 2019 according to the current development trend of aseptic filling technology and the individual needs of industry customers. The equipment integrates "multifunctional aseptic filling" technology, and one piece of equipment can meet the production needs of customers for a variety of aseptic products, thus promoting the aseptic filling technology to a new stage.
In September 2021, Baiguan participated in the national key scientific research project during the 13th Five-Year Plan and successfully passed the acceptance test, among which 36000 (b/h) multifunctional sterile line was rated as "the initial creation in China, the first-class technology in the world and the replaceable imports" by the expert committee of the Ministry of Science and Technology. The user's field equipment is in good use, and the aseptic maintenance is stable and reliable, which can meet the innovative demand of customers that one aseptic filling line can produce multi-category products. This article analyzes and summarizes the technological characteristics and main structural innovations of Baiguan's multifunctional aseptic production lines.
1. Classification of aseptic filling products of PET bottles
1) Classification of pH value of materials: high acid products, pH value ≤4.5. Low-acid products, with pH > 4.5, with pH between 6 and 7, are defined as neutral products.
2) Classification of material contents: clear juice, cloudy juice, low viscosity, high viscosity, Contains fiber, fruit, etc.
3) Classification of filling methods: contact filling and non-contact filling.
4) Classification of packaging forms: carbonated products and non-carbonated products.
2. The definition of multifunctional aseptic filling technology
After years of practice, the author thinks that the definition of multifunctional aseptic filling technology should be: a set of the aseptic filling production lines, which can meet the requirements of filling neutral products, multi-content compatible filling capacity, contact filling capacity and non-contact filling capacity, and can be quickly switched and meet the filling technology of compatible filling capacity of gas-containing products and gas-free products.
Baiguan multifunctional filling production line has the multifunctional filling technology defined above, and at the same time, it reaches the domestic advanced level in terms of equipment quality and aseptic safety, and the production cycle reaches a 120-hour aseptic production cycle. This series of multifunctional aseptic filling production lines integrate a special aseptic mixing system, and the aseptic technological process is developed by a mature "wet sterilization" platform, which has more than 60 mature cases in domestic industries, and its microbial safety and mechanical stability are mature and reliable. The equipment is fully compatible with carbonic acid/non-carbonic acid aseptic production and can be extended to sensitive non-carbonic acid-neutral products, compatible with filling with fruit grains, fiber filling and filling with high and low viscosity materials.
3. Technological Requirements for Multifunctional Sterile Production
The key of aseptic filling technology is to ensure that the microorganisms inside the beverage after filling and capping are controlled within the allowable range, that is, to achieve "commercial sterility".
In order to ensure the success of aseptic filling, the production line must meet the following basic requirements:
1) Sterile feed liquid—UHT sterilization and aseptic tank storage, with aseptic maintenance period ≥120 hours
2) Establishment of the sterile environment—filling the sterile area of the host machine and establishing a sterile environment through standard COP/CIP/SIP/SOP procedures
3) Maintenance of sterile environment—filtering ambient air with high efficiency or maintaining positive environmental pressure to maintain a sterile environment
4) Sterility of empty bottles and lids—achieving the aseptic state of packaging materials through PAA wet sterilization
7) Mixing ratio of materials and CO2—realization of aseptic mixing ratio process
4. Production process flow of multifunctional aseptic filling (aseptic carbonic acid filling)
This is a standard multifunctional aseptic filling production process, which meets the requirements of traditional conventional aseptic filling and carbonic acid aseptic filling. In the original standard aseptic filling process, CO2 aseptic treatment and aseptic mixing of materials and CO2 are added. At the same time, the multifunctional aseptic filling valve is adopted in the aseptic filling host filling system, which can realize non-carbonic acid, non-contact filling and carbonic acid contact filling. At the same time, the aseptic line adopts the standard neutral medium verification scheme, which needs to verify the aseptic performance of the aseptic mixing ratio system, aseptic filling machine system and aseptic tank system, and meet the verification standard of 120 hours.
5. Design requirements of GWJX25HP multifunctional aseptic filling machines
Output Speed of non-carbonic acid blowing, filling and rotating main machines: 40000 b/h (500mL) Speed of carbonic acid blowing and spinning main machines: 36000 b/h (500mL)
Scope of application filling capacity: 250 ml - 1500 ml
Bottle diameter: 50 mm - 100 mm
Bottle height range: 150 mm - 300 mm
Bottle blank material: PET, bottleneck 28mm
6. Aseptic process parameters of project design
Project & Design Parameters:
Aseptic water requirement: Sterilization intensity＞6 log In-bottle sterilization intensity ≥6log
Packaging material sterilization requirements: Sterilization intensity outside the bottle ≥5log Sterilization strength of bottle cap ≥6log
The most critical technological parameter for the safety and stability of aseptic filling is the establishment and sterilization of the equipment. Through years of experience accumulation, the author's team thoroughly sterilized the packaging materials and machine environment by using the currently safe wet sterilization method and stably reached the sterilization strength requirements in the table.
7. Main structure and characteristics of multifunctional aseptic filling machines
Multi-functional aseptic blowing and filling rotary production line mainly includes clean bottle blowing unit, empty bottle sterilization unit, sterile water bottle flushing unit, multifunctional filling unit, servo capping unit and capping sterilization unit. Auxiliary equipment includes sterile water preparation unit, disinfectant preparation unit, sterile valve group control unit, sterile buffer unit, CIP online cleaning unit, tail gas neutralization and discharge unit, chemical supply center and other equipment. Baiguan multifunctional aseptic filling production line integrates a number of self-developed new technologies-multifunctional aseptic filling valves, isolated bottle lifting system, filling aseptic gas path separation system, product loop aseptic maintenance system, aseptic high-speed servo capping system, empty bottle injection pressure detection modules, aseptic gas-liquid mixers, etc.
Aseptic filling system and filling valves are key components of aseptic filling equipment. The rationality of the structural design of multifunctional filling valves is related to the stability and reliability of the aseptic filling process, which is an important guarantee to realize multifunctional filling. Baiguan researchers have carried out the innovative design of the filling valve structure and developed a multifunctional aseptic filling valve based on standard central pillar filling technology, which adopts contact isobaric filling of carbonic acid products and non-contact non-isobaric filling of non-carbonic acid products. The filling valve has both coarse and fine double-speed filling mode to ensure high precision of filling capacity. The back pressure of the filling valve and the pressure relief in the bottle is designed by an independent loop system, and this isolated structural design can ensure aseptic safety. Compatible with the simultaneous filling of carbonated or non-carbonated products, without any change parts (the same bottleneck size). The "telescopic seal" of the central column of the filling valve is made of imported composite materials to ensure the stable and reliable quality of key components. The filling valve can be filled with fiber or 3×3×3 fruit products (non-contact). The filling valve can carry out the standard CIP cleaning and SIP sterilization process under the condition of aseptic filling manufacturability, and all key seals and springs can meet the standard requirement of annual maintenance time ≥ 6,000 hours.
7.2 Technical innovation—isolated bottle lifting system
During the filling process, the component should meet its reciprocating motion up and down, and at the same time realize the internal and external mechanical isolation function of the sliding part of the aseptic filling machine. The mechanism is integrated with the multifunctional filling valve, and the maintenance is simple. The design scheme adopts a fully automatic lifting mechanism. Automatically set the "lifting and non-lifting" status according to product characteristics, and complete the functions of contact filling of carbonated products and non-contact filling of non-carbonated products. An independent driving system is arranged outside the filling isolation cover to realize the up-and-down movement, and the internal and external non-contact isolation is realized through dynamic "telescopic sealing".
7.3 The control process of product filling process (carbonated filling and non-carbonated filling)
Carbonic acid filling process: empty bottle-feeding → inflation isobaric → slow filling → quick filling → slow filling → valve closing and standing → venting → standing → venting → real bottle discharging. According to the formula characteristics of materials and products, the filling process can be adjusted to "quick filling-slow filling” or fully quick filling.
Non-carbonic acid filling process: empty bottle-feeding → slow filling → fast filling → slow filling → valve closing and standing → real bottle discharging. Similarly, according to the formula characteristics of materials and products, the filling process can be adjusted to "quick filling-slow filling" or "fully quick filling".
Carbonated filling mode and non-carbonated filling mode can realize the online conversion of product category and product formula with one key (quick conversion between contact filling and non-contact filling) through the program. The setting time of each station can realize convenient parameter adjustment on the man-machine interface according to the product material characteristics, so as to achieve a stable filling process.
7.4 Technical innovation—aseptic mixing system (carbonic acid aseptic)
The equipment is an important equipment in the aseptic carbonic acid production process. First, the equipment needs to realize the aseptic design requirements of internal material channels. At the same time, it needs to complete the automatic online mixing of CO2 according to the requirements of gas-liquid mixing. The system is equipped with aseptic storage tanks for mixed materials. The key mixing ratio core hardware uses a mass flowmeter to control CO2 mixing accuracy. At the same time, according to the customer's requirements, the aseptic CO2 online monitor can be selected, the tube heat exchange and cooling system are standard, and the independent and dedicated CIP cleaning and SIP sterilization function is integrated to meet the aseptic technological requirements of the equipment. The system is equipped with a quick-filling product switching device.
Technical parameters of equipment: CO2 content: 3g/L - 8.4g/L (at 6℃ - 12℃) Mixing accuracy: ≤±0.1vol
7.5 The spraying sterilization of empty bottles In-bottle sterilization: This unit adopts the standard double-tray wet spray sterilization method, the cumulative sterilization time is more than 10s, and the bottle flushing nozzle is made of corrosion-resistant polymer material, which has strong mechanical flushing force and improves the chemical effect of bactericide, and even cold stains can be easily removed. The nozzle can be extended into the bottle to reduce the dead angle of washing and improve the sterilization efficiency, and the sterilization intensity is guaranteed to be ≥6log. There is a nozzle spray pressure detection sensor, which has the function of "monitoring and alarming" nozzle spray pressure, and ensures that the nozzle spray pressure is greater than 2.5bar. Sterilization outside the bottle: the fan-shaped nozzle with a customized angle is used, which has strong mechanical and chemical processing ability, and can completely sterilize the outside of the empty bottle. The sterilization positions include the mouth, neck, body and bottom of the bottle. Nozzles are arranged with multiple nozzles in the upper, middle and lower layers, and the ultimate goal is to achieve sterilization intensity ≥5log outside the bottle. At present, with wet sterilization, the sterilization intensity in the bottle can reach the required sterilization intensity very reliably, and the equipment design needs to pay attention to the residual control technology of the disinfectant.
7.6 Cover sterilization, washing and conveying unit Cover sterilization, washing and conveying system, the sterilization part adopts spiral disc conveying structure, soaking spray sterilization mode, ensuring sterilization time >60s, and multiple groups of nozzles are arranged inside the cover sterilization tank, ensuring strong mechanical and chemical treatment effect, and ensuring that the cover can achieve comprehensive sterilization with sterilization intensity≥6log. Through the sterile water spraying section, sterile gas blowing and draining section and conveying section, the peroxide residue of the lid is finally guaranteed to be less than ＜0.5ppm. At the same time, the system is equipped with a "tubular heat exchange tube" to control the temperature of the cover at about 45℃, so as to ensure that the temperature rise of the cover is within a reasonable range in the process of disinfection and to avoid overheating and deformation of the cover, which will lead to unstable quality and low torque in the later screwing of the cover.
7.7 Sterile water flushing unit The washing unit is equipped with a uniquely designed spiral nozzle, which ensures the uniform distribution of sterile water jet water flow, with the jetting pressure over 2.5bar. The sterile water jet adopts a multi-stage intermittent jetting method, which has high washing efficiency in the bottle and low water consumption, and at the same time ensures that the peroxide residue is less than 0.5ppm. When the nozzle is blocked, the system must give an alarm in time. Baiguan developed a special high-speed jetting pressure detection sensor system, which has a high/low pressure "monitoring and alarming" function.
7.8 Technical innovation item-high-speed aseptic servo capping system This system belongs to the first "high-speed aseptic servo capping" system in China. Preparation of integrated servo motor and controller+aseptic isolation technology+aseptic capping head. Compared with the traditional mechanical capping system, the servo capping system has the following advantages: the dead angle in the sterile area is the least, and it is easier for COP cleaning and SOP disinfection of equipment to achieve no dead angle coverage. The adjustment of the equipment is simple and convenient when replacing the cover, and the adjustment of the torque of screwing the cover is simple and convenient when the carbonated/non-carbonated products are switched, thus ensuring the matching between the torque and different covers. The internal and external aseptic isolation adopts electric heating barrier technology: the lifting arm of the screw cap is equipped with the electric heating coil to realize high-temperature aseptic isolation, and the temperature of the electric heating barrier is greater than 100℃. Ensure complete inactivation of microorganisms, and have a low-temperature alarm function. At the same time, the self-developed servo capping software control program has the function of quickly switching between "abnormal capping torque" monitoring alarm and "capping formula" in the production process.
8. The multifunctional aseptic filling production line of the GWJX series
Food safety: Wet sterilization—a mature and stable sterilization technology in the industry Ensure that the sterilization ability in the bottle and lid are≥6log. Ensure the sterilization capacity of sterile space ≥6log. Ensure that the external sterilization ability of the bottle is ≥5log. Multifunctional aseptic filling valve to meet the aseptic safety of various filling and filling methods. The peroxide residue of packaging materials is ＜0.5ppm
Filling product compatibility: Compatible with various products: carbonic acid/non-carbonic acid, high acid/low acid, high viscosity and fruit (3×3×3) Quick product change and quick aseptic switching Simple and convenient switching cover type (servo screw cover)
Mechanical productivity efficiency Up to 120 hours of the continuous production cycle of high and low acid products There is no need for short sterilization in the production cycle The production efficiency of blowing, irrigation and spinning machines is ≥95% Application of customizable aseptic filling equipment
9. Equipment popularization and application As parts of the GWJX series multifunctional aseptic filling production line, the first prototype was installed in Anhui Chuzhou Yuanqi Factory in May 2020. After nearly two months of production line connection and aseptic filling system debugging, it passed the 120-hour neutral medium verification in July of the same year and was put into production smoothly. Aseptic filling products include a series of bubble water, aerated 100% fruit juice, burning tea and other products, realizing the multifunctional production of aseptic filling. After testing, the product quality has reached the customer's approval, and the main technical indicators such as output and energy consumption lead or surpass the international similar products.
At present, Baiguan multifunctional aseptic filling production line series includes GWJX25HP series, production speed—aseptic non-carbonated filling 40000 (b/h), aseptic carbonic acid 36000 (b/h); GWJX15HP series, production speed—aseptic non-carbonated filling 24000 (b/h), aseptic carbonic acid 20000 (b/h); GWJX10HP series, production speed—aseptic non-carbonated filling 18000 (b/h), aseptic carbonic acid 12000 (b/h), so as to meet different choices and production needs of customers.