Application of Dry Sterilization Technology in Filling Production Line

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The beverage producer are chasing for the ultra-high speed of the line, light weight of the packaging material, low energy consumption of the machine etc. and the demand for the high-end technology equipment which can cater for the market changing is becoming more stringent. Newamstar, as the leading liquid product packaging machinery supplier in China, who initiatively proposed the dry sterilization technology by using H202 and peracetic acid, which has already been used in the Combi production line and Aceptic cold filling production line, for PET bottled water, beverage and dairy product. The application of dry sterilization technology can reduce the consumption of chemical product and the bottle rinsing water dramatically, due to the same sterilization effect under the low concentration compared with the wet sterilization.

Newamstar is the explorer and founder in China on PET bottle Aseptic cold filling technology, working and researching in the Aseptic filing technology field for decades. The Aseptic technology is continuously innovated and improved, as well the VHP and HPV system is developed exclusively by Newamstar on packaging material sterilization topic. A series of the sterilization intensity theoretical figures are collected through the cooperation with Jiangnan University, verifying the microorganism in the laboratory. And such technology has been successfully applied on the non-ozone mineral water Combi production line, Aseptic cold filling and cold filling production line etc. The low concentration (1-3mg/L), low temperature (20-50℃) gaseous H202, achieving the sterilization level ≥5log in a short time.

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H202 wet sterilization and dry sterilization efficiency comparison in the condition of same concentration (Test Figure)

Preform dry sterilization technology

The dry gas spray device is installed before the preform entering the heat oven, gaseous H2O2 is evenly sprayed to the internal surface of preform. The H202 will be activated by the heating process in the heat oven and the sterilization effect will be intensified, result in the decrease of bacteria number in the preform. The H202 will be evaporated by decomposition instantaneously by the means of high temperature heating after the preform is sterilized by H2O2. The whole technical process design is simple while reliable. The technology not only reduces the risk of H202 residual inside the preform, but also realize the high hygienic safety level target. Newamstar brings the H202 dry sterilization technology into mineral bottled water Combi system, which makes the product more safe and reliable and it is verified at customer’s factory and approved by customers.

Cap dry sterilization technology

The traditional cap sterilization technical process normally use the wet sterilization type that uses the disinfectant to soak the cap for certain time. The advantage of such method is the intensity of the sterilization is high, stability and reliability is good while disadvantage is that it requests large amount of the recycling disinfectant to be used, the sterile water is necessary to rinsing the cap and wash away the residual disinfectant in the cap, so the high consumption of the water is the most disadvantage for wet sterilization. Newamstar has released the combined scenarios by using UV middle pressure sterilization and H202 dry sterilization after the research and analysis. The sterilization scenario is divided into 2 steps due to the internal special structure of the cap. The first step is to sterilize the cap by using the middle pressure UV lamp, which de-activates the bacteria, virus, spores and other pathogenic bacteria, the effect of the sterilization can reach ≥3log. Then the 2nd step is to use the spraying gaseous H202 to sterilize the cap, which takes the sterilization effect to ≥5log. In such way, only few of the disinfectant is used and without the consumption of water, however, the through sterilization can be achieved. For the Aseptic production line with 36000BPH, more than 5000l/h water can be saved only in the cap treatment stage.

Application of Dry Sterilization Technology in Filling Production Line

Empty bottle dry sterilization technology

Currently, the lactobacillus milk stored in low temperature is more and more popular for consumers, not only because of the high nutrition of the product itself but also to some extent it can improve the physiological function of the body. Then, how to catch this product market share by mean s of extending the shelf life of the product in the base that the product quality is guaranteed. Newamstar solved such issue for customer in the real production in the means of settling the technical challenge one by one concerning the packaging material sterilization. The empty bottle dry sterilization and sterile hot wind decomposition technology is well applied on the cold chain filling production, and it makes it a possible that the packaging material can be thoroughly sterilized on the one hand, on the other hand the quality and safety of the lactobacillus beverage and high&kow acid beverage in low temperature can be adequately assured. The gaseous H202 will be sprayed into the bottle evenly, the log level of the sterilization can be realized after the microorganism is inactive through the condensing procedure. Afterwards, the sterile hot wind system decomposes the H202 in a short time to ensure that no any residuals will pass to the filling procedure. The sterilization can be used for all kinds bottle shape (square bottle, round bottle), bottle size (0.2-1.5L). By using such sterilization method, for one 36000BPH filling production line, 5000-10000L/H rinsing water can be saved while the sterilization effect can be guaranteed.

Isolated cabinet dry sterilization technology

Isolated cabinet is one of the key parts in the Aseptic production line, so the sterilization of this part will matter for the whole process. The isolated cabinet PAA spray fumigation sterilization technology is researched and developed by Newamstar, to guarantee the product safety more efficiently. The liquid H2O2 is vaporized instantly by the hygienic steam, and the steam with 1000-1500ppm is sprayed into the cabinet, the internal sterilization can be done in short time. In the real production, the Aseptic filler isolated cabinet is verified with respect to all regulations and rules.

Nowadays, the dry sterilization technology developed by Newamstar is already widely used in all kinds of the system and production lines, and well accepted by the customer in market. The technology can make the product safe and at the same time the energy consumption will be reduced, which can make considerable economic benefits.

NEWAMSTAR HIGH-SPEED BLOWING-FILLING-CAPPING COMBIBLOCK

Newamstar High-speed Blowing-filling-capping Combiblock combines the blowing system, filling system and capping system in one integrated system, reducing several intermediaries suchas transmission, empty bottle handling and storage processes, which improves packaging hygienic condition and reduces packaging ross-contamination so as to improve the overall operating efficiencybut lower the energy consumption, thereby reduces the overall production cost of enterprises.

  • Product Range: Production capacity from 12,000 BPH to 80,000 BPH.
  • Applications: It is applied to PET bottled pure water, carbonated soft drink, juice, liquid dairy, liquid condiment and household & personal care products, etc.
Newamstar High-speed Blowing-filling-capping Combiblock

Stable infrared ray heating system and independent heat balance device ensure the stable temperature of the preform, even color of the bottle and increase of the output.

Special designed twice-blowing system can monitor the pressure in each mold in order to provide accurate real-time parameter for operator. It is easy for the operator to adjust the parameter and ensure the stability of bottle forming.

High-speed and high-accuracy diaphragm type filling valve: Equip air back channel which is separated from liquid carousel, by which, the air replaced from the PET bottle won’t enter liquid carousel to avoid second pollution. Equip cleaning dummy bottles which can realize online CIP.

Sanitary and washable capper:Optimized cam surface design ensures the minimum
impact force of the capper .Bottle discharging starwheel is screwing decently, so it is unnecessary to adjust the conveyor height during bottle format change.

Driven by innovation and win the market by quality!

Newamstar has focused on liquid packaging industry since from its establishment. Taking innovation as guide and basis, we have been forging ahead constantly.

As an outstanding company in China high-end equipment industry, Newamstar has built a dimensional product system gradually including beverage, milk, alcohol, condiment and daily used chemicals. We have won many innovative “China First” for various products. All these achievements and milestones will be fixed and memorized in the long history of Newamstar.

INTELLIGENT STEREOSCOPIC WAREHOUSE SYSTEM: THE FIRST CHOICE OF BEVERAGE FACTORY TO UPGRADE THE MODERN WAREHOUSING AND LOGISTICS!

In recent years, with the increasing of automation and production capacity of liquid food packing line, contradictions between inventory and production capacity have become increasingly prominent. At the same time, with the increase of land cost and labor cost,traditional discrete model of warehousing and logistics using single logistics equipment or personnel to carry out the transportation of product and raw materials has been outdated.

With the deepening of “industry 4.0” and “Internet +” concept, the Chinese industry is transforming from the traditional labor-intensive to the industrial automation, and the traditional management mode based on people is turning to computer-based Information and modern management. Intelligent equipment represented by robot and a new generation oflogistics model with the function of data collection, management and data tracing is being more widely used in the market.

Intelligent stereoscopic warehouse system: the first choice of beverage factory to upgrade the modern warehousing and logistics

As the Chinese leader in the field of liquid packaging, Newamstar accumulated rich experience in long-term development. By industry research, product technology development and the integration of industry resources over one year, Newamstar introduced the concept of “Internet +” into the production line followed by the pace of “Industry 4.0”. On the basis of rising the capacity and stability of liquid packaging production line, Newamstaroptimized the structure of production lines and improved the level of automation of the production line by reducing the cost, and improving the quality and efficiency.

System composition:

  • Goods transition and storage – high rise shelf, tray and container.
  • Check in & out device – palletizer.
  • Check in & out distribution system – roller and chain conveyor, distributing vehicle, lifter, etc.
  • WCS control system – includes check in-out device controlled by computer, distribution system, various kinds of inspection and safety device controlled by electricity.
  • WMS warehouse management system – warehouse account management, data analyzing, goods site arrangement, device operation and warehouse storage display, etc.

A double extension tunnel stacking machine is adopted in the projects of“Moon over a Fountain Co. Ltd”, which achieve an effective balance between capacity and efficiency by improving space utilization and flexibility of warehousing in a limited space. The production line is connected with the warehouse directly, so a lot of material transfer links was saved. With advance internet technology, it realizes the resources and data sharing and connection between the ERP(enterprise resource management system), MES (manufacturing execution system) and WMS (warehouse management system) to reduce the mistakes and speed up access of the goods. Compared with the traditional discrete warehouse,  Intelligent stereoscopic warehouse system can save the cost of land investment, reduce labor intensity, improve the working environment and reduce labor costs, finally improve the production efficiency and the level of modern management by making packaging and storage systemIntegrated, automated and intelligent.

In 2015, with excellent R&D design team and processing advantages of equipment manufacturing, Newamstar completed the development of automated warehouse system with tunnel stackerand RGV rail transport trolley. In the same year, Newamstar successfully presented it on CBST exhibition in Shanghai, and received wide attention from lots of companies in the industry. In 2016, automated material transport under special circumstances is solved by researching and developing non-rail AGV transport trolley. Through the introduction of advanced visual logistics simulation software FlexSimand excellent simulation designers, we can make simulation test in the project planning process, and do all kinds of system analysis and engineering verification for the model to get the final optimized the design. It can also quickly confirm the logistic equipment solution, further verify the feasibility of the project, provide improving and management basic data for the system, and reduce operating costs of production enterprises.

Currently, Newamstar are upgrading internal logistic systembased on stereoscopic warehouse system, will build automated logistics system by using AGV non-rail Intelligent trolley to distribute the raw materials, and create a new automated management system with the product lifecycle management, process management and information management.

New age, a new chapter, a new dream. With the evolution and promotion of intelligent stereoscopic warehouse system, it will help beverage manufacturers to clarify and refine requirements, quantify data target and accuracy control of the production process, and finally help to realize the intelligent, automation and modernization of plant.

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