Stretch blow molder with high energy savings gentle on the environment
With the integration of the stretch blow molder the aseptic block gains a number of further plus points. One of these is that the heating system in the new Blomax generation consumes up to 40% less energy compared to most standard heating systems thanks to its optimized near infrared heating concept and new Double Gate technology. This is made possible by the near infrared heater centrally installed in the closed reflector tunnel. In the heater the preforms pass the centrally arranged heating units to both the left and right. The preforms are spaced just around 18 millimeters apart instead of the previous approximately 37 millimeters. The Dortmund systems supplier has thus been able to considerably reduce the number of heater boxes used. The air management system for heater box ventilation has also been optimized. “The fan can be set separately for the neck, reflector and lamps. This means that the machine only cools the areas which actually need cooling,” explains Redeker.
Effective sterilization with the KHS system
When further developing its linear aseptic filler KHS also focused on increased efficiency. The filling machine for sensitive products is available in both a standard aseptic and ESL version. In the KHS process sterilization takes place in several stages. First, the machine disinfects the neck and bottle interior. Here, the inside of the container is sprayed twice with a hydrogen peroxide aerosol (H2O2) at a speed of up to 80 kilometers an hour. “This ensures that every part of the bottle is sprayed and sterilized; we even achieve this with individual designs and critical shapes,” Redeker states. Secondly, two aerosol reaction cycles are initiated. The process ends with a four-stage drying process which uses sterile hot air.
Gentle filling ensures product protection
In order to ensure the quality of the products, it is essential that the aseptic zone is absolutely clean. KHS ensures this by gentle non-contact filling, among other things, performed in two stages. This prevents any excessive beverage foaming.
After filling the bottle is conveyed to the capping unit. Here, the closure is sterilized in the same manner as the bottle in the filling section. This entails two-step disinfection with H2O2 and two drying stages with hot sterile air. “In the capper unit we’ve also made sure that all parts in the aseptic zone have a flat surface. By doing so we can prevent any air turbulence, making cleaning and disinfection easier,” Redeker comments. The bottle is then dated for full documentation of all information. “Our customers can always see which product was filled when on which valve,” explains Redeker.
With its new dry aseptic block KHS has reacted to the current dairy demand for flexible, resource-saving filling of sensitive products. The new system also boosts line availability and considerably reduces energy consumption. Operators also have greater flexibility thanks to the short changeover times: format changes are facilitated by the well-coordinated interfaces. The modular design also enables customers to expand their linear aseptic filler block in order to meet current market demands at all times.