MOVING IDEAS
Filling systems in the beverages industry Filling and bottle treatment technologies for bottling water, soft drinks, spirits and other products of the beverages industry
Text by Manuel Bolzoni, Gabriele Folli, Glauco Cima, Carlo Nucci, Ermes Battistini
OCME Competence Library
www.ocme.com
Machine series
OCME designs, manufactures and installs filling, packaging, palletising and handling machines for all the major mass consumer product manufacturing sectors. OCME machines are the result of decades of experience and are designed to become the backbone of our Customers’ production division.
High and low level depalletisers
DORADO ANTARES
Roll-fed labeller
SAGITTA
Level filler for beverages
HYDRA
In-line and rotary volumetric fillers
LYNX
In-line and rotary weight fillers
LIBRA
Shrink-wrap and tray-packers
VEGA
Wraparound packers
ALTAIR
Combined wraparound and shrink-wrap packers
GEMINI
High and low level palletisers with 90° infeed
PERSEUS
In-line high and low level palletisers
ORION
Robot palletisers
PEGASUS
Automated guided vehicles
AURIGA
Computerised control system
ALBATROS
Filling systems in the beverages industry Filling and bottle treatment technologies for bottling water, soft drinks, spirits and other products of the beverages industry
Contents Filling bottles for tomorrow’s consumers
5
Filling systems: comparing technologies
6
Comparing technologies
7
Which products to handle
8
Hydra and Libra fillers: the machines in detail
9
Hydra, level and flow meter fillers
12
Features shared by all Hydra models
19
Libra R5: electronic weight filler
20
Libra R5 for spirits
22
Libra R5 for 5 gallon bottles
23
Hygiene and safety for food products
24
The ideal plant in the beverages industry
28
Complementary machines for the filling line
30
The marketing value of filling machines
33
Environmental respect
34
OCME Competence Library
www.ocme.com
5
Filling bottles for tomorrow’s consumers
....Good ideas alone are not enough; you also have to know how to package them. Anonymous
i
n a literal sense, filling is no more than the task carried out by a machine that packages liquid products such as drinks or water. Nonetheless, for modern-day companies, the apparent simplicity of this phrase hides a plethora of variables and possibilities that embrace all the types of containers and caps and all the materials used in their manufacture and the nature of the product to be filled, as well as by no means secondary aspects associated to productivity, precision, overall cost of the filling technology and the environmental impact of the production sites. Today, more than ever before, the beverages market offers opportunities that may be seized only by companies that have the technology it takes to keep them one step ahead of the competition. The birth of new types of products, the growth of the private brand market and the need for constant differentiation (in terms of both packaging and format) demonstrate that a high degree of flexibility is a priority. Essential conditions to render flexibility a real advantage are efficiency and the total availability of the bottling line. It’s easy to think of a filling machine as the sole, nerve core of a system, but in actual fact, every machine located upstream and downstream is just as important, and the perfect coordination between the “wet area” and the “dry area”, including all the plant’s internal logistic issues, determine a company’s real capacity to fulfil customer requests. Paraphrasing a basic marketing rule, one could say that the company’s task, and therefore the manufacturing technology used by the company, no longer ends with a filled and capped bottle, but rather with a sold and appreciated bottle, hence maximising commitment and results.
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OCME: Filling systems in the beverages industry
Filling systems: Comparing technologies
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A bottle is filled when the liquid is transferred from the tank to the container itself. That which distinguishes one filling technology from another is the way in which the correct quantity of product is supplied. Different systems and different technologies may be used. Principally, these may be divided into three categories: filling by level sensing, using volumetric flow meters and by weight. Of these three systems, the level sensing system is consolidated by years of use in the beverages sector, as it is predominantly tied to mechanical devices. Ocme machines for the beverage industry use both level technology and electronic weight technology or volumetric
flow meters. In the latter two cases, a sensor (which may either be a scale with a load cell or a mass or magnetic indicator, depending on the technology used) enables or interrupts the flow of product towards the bottle, so as to obtain the correct amount of product inside the container, based on the production settings. Industry literature provides for another type of filling machine, belonging to the volumetric family, known as a piston-filler. These are prevalently mechanical machines into which a given volume of product is transferred by means of the action of a piston. Seeing as this type of technology is not important in the beverages sector, it will not be dealt with in this brochure.
7
Comparing technologies
By level sensing These are the most traditional and commonly used types of filling machines. The fill level is determined by the length of the tube that enters the bottle, during the filling stage. Generally speaking, to change the level in the bottle, the tube must also be changed.
By flow meters These types of filling machines measure the volume of the product entering the bottle. A flow meter (with either a mass or magnetic indicator) fitted on every filling nozzle gauges the volume. These are called electronic filling machines.
By weight This type of filling machine measures the weight of the product entering the bottle, after having taken the tare weight of the container. A load cell for each filling valve measures the weight. These are electronic machines par excellence.
By level sensing
By volumetric flow metre
By weight
Precision
=
+
+
Variability based on ambient conditions
=
+
+
Maintenance
+
=
=
Format change
=
+
+
Ease of sanitisation
=
+
+
Key:
+ = positive
= = neutral
- = negative
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OCME: Filling systems in the beverages industry
Which products to handle
T
he Ocme series of filling machines consents choosing the right technology to handle a vast number of products, both strictly for beverages as well as for other food liquids of various types. To choose the ideal machine, various factors must be considered, such as for example, the type of product, the type of container and the material used for the container, but also the degree of precision required and the production volume. The Ocme series of machines is designed to cover a wide range of possibilities, allowing companies in the beverages sector to cover everything from small or medium production
volumes to large or very large volumes. Along with the Hydra machines, specially designed and built to meet the needs of companies in the beverages sector, Ocme also offers the Libra series of filling machines, which derive from the high production and efficiency filling systems used in other consumer goods industrial sectors. These latter machines, the Libra series, are used for large scale productions of gallon bottles containing still water (bottles containing up to 10 litres), or as a weight-based alternative to volumetric filling for the spirit and wine sector, where the high value of the product makes the Ocme high-precision weight system technology particularly appealing.
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Hydra and Libra fillers: The machines in detail
Here below is the list of the range of OCME filling machine models for the beverages industry. HYDRA N Filling for still liquids. This filling machine is a “mechanical” type machine and uses the “level” filling system. Gravity filling by atmospheric pressure. The machine is equipped with an annular tank and has an extremely rational design. The presence of the bottle opens the valve. The machine is easy to sanitise thanks to a series of devices studied especially for this purpose. HYDRA I Filling for still and carbonated liquids; may also be used for still products alone. Ocme has designed this type of filling machine by combining leading-edge electronic and pneumatic technological solutions. Hence, this is a level filler that may be classified “electro-pneumatic”. To handle carbonated products, the product
tank must be pressurised, but this machine may also handle still products and, in this case, it works at atmospheric pressure. The machine is equipped with an annular tank and is mechanically and structurally built in a simple and rational manner. The machine uses the same sanitising systems as the Hydra N machine. HYDRA I-AR Filling for carbonated products; may also be used for still products, with separated air return system in order to eliminate any risk of contamination. It has the same design characteristics as the Hydra-I machine, with an added separated air return circuit that prevents contamination hazards and avoids having to introduce nitrogen or sterilised air into the filling circuit. The separated air return system consents filling for still products without the need to pressurise, hence avoiding the risk of deforming the container and therefore permitting the use of thinner-walled bottles.
10 OCME: Filling systems in the beverages industry
HYDRA N-V Filling for alcoholic products (spirits, etc.). This type of filler has been designed by combining electronics and pneumatics. It may be defined as an “electro-pneumatic control” machine that works “by level”. This filling method is carried out by taking advantage of a slight negative pressure in the tank, hence providing the following advantages: • allows for “auto-level” in the bottle and hence for very precise fill levels • the slight negative pressure means that not even a drop of product is wasted • independent vacuum management for each filling valve The latter two characteristics are extremely appreciated when filling expensive products. Moreover, this method consents varying the level in the bottle within a 25 mm range without having to change the filling spouts.
HYDRA M Rotary filler with a flow meter (either magnetic or mass, depending on the application). This machine is manufactured with a minimum of 32 valves and up to a maximum 120. It is suited to filling any size or shape bottle, either glass or PET, with extreme volumetric precision. Production output from 8000 bph to over 100,000 bph. Suited to filling still products at room temperature or hot. LIBRA R5 Electronic rotary weight fillers designed to fill still liquids. Typical applications for this type of machine include filling 5-10 litre natural water bottles at high output speeds and filling spirits.
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Still products Machine model
Type of product
Number of nozzles (from... to...)
Container types
Container formats
Technology used
Speed (referred to a 1.5 l PET still water container)
Maximum speed reached
Hydra N
Still water, Wine, Non-carbonated drinks
32-120
PET, glass bottles
from 0,25 to 2,5 lt
Gravity level filling
10.000 – 50.000
100.000
Hydra M
Still water, Juices, Non-carbonated drinks
32-120
PET, glass bottles
from 0,25 to 2,5 lt
Flow metre filling
10.000 – 50.000
100.000
8-42
Large containers (i.e. 5 gallons PET bottles)
from 5 to 10 lt
Electronic weight filling
1.500 – 12.000 *
12.000
Libra R5
Still water
* Speed referred to a 5 litre still water container
Carbonated products Machine model
Type of product
Number of nozzles (from... to...)
Container types
Container formats
Technology used
Speed (referred to a 1.5 l PET still water container)
Maximum speed reached
Hydra I
Carbonated and flat water, beer, carbonated drinks, still wine, sparkling wine, drinks with an alcohol content
32-120
PET, glass bottles
from 0,25 to 2,5 lt
Isobaric level filling
6.000 – 50.000
100.000
Hydra I-AR
Carbonated and flat water, beer, carbonated drinks, still wine, sparkling wine, drinks with an alcohol content
6.000 – 50.000
100.000
from 0,25 to 2,5 lt
Isobaric level filling with separated air return
32-168
PET, glass bottles
Number of nozzles (from... to...)
Container types
Container formats
Technology used
from 0,25 to 2,5 lt
Gravity level filler with 8.000 – 40.000 slight negative pressure
50.000
from 0,25 to 2,5 lt
Electronic weight filler
40.000
Spirits Machine model
Type of product
Hydra N-V
Spirits
32-120
PET, glass bottles
Libra R5
Spirits
16-84
PET, glass bottles
Speed Maximum speed (referred to a 0.75 l glass reached container)
3.000 – 30.000
12 OCME: Filling systems in the beverages industry
Hydra, level and flow meter fillers
T
he Hydra series of machines comprises fillers that have been specially designed for the beverages industry. The design was born to permit the integration of high-performance and high-flexibility machines into the already vast range of Ocme solutions for the beverages sector. Hydra is a series of fillers that have been designed to handle a wide variety of products, bottles and production speeds. Starting from the two standard models, Hydra N for still liquids and Hydra I for still and carbonated liquids, the series includes machines with from 32 to 168 filling valves for a production output that ranges from 12,000 to 100,000 bph. The isobaric version is also available in the Hydra I-AR configuration, with separated air return.
The pitches used for bottle handling allow for great flexibility and, most of all, enable adapting the machine to the type of production required by the customer. Pitch ranges are: • 94 mm for bottles max Ø 89 mm; • 113mm for bottles max Ø 108 mm; • 126mm for bottles max Ø 120 mm; • 141mm for bottles max Ø 130 mm. Lastly, Hydra M is the series of beverage fillers designed for still liquids and equipped with flow meters, with 32 and 120 filling valve models, for a production output range between 12,000 and 100,000 bph.
1
2
4
Figure 1 Passing starwheel between the filler and the capping machine.
Figure 2 Filling carousel with bottle lifters for glass bottles.
Figure 3 Capping machine for glass bottles.
Figure 4 Starwheel for filler infeed.
3
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14 OCME: Filling systems in the beverages industry
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HYDRA-N Gravity level filling valve
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HYDRA I Isobaric level filling valve
A
A B
B
C
C A Separated air return channel
A Upper electropneumatic valve
D
B Membrane
E
C Tank D Separated air return pipe
F
E Filling valve F Deflector G Air evacuation pipe
E
C Tank D Spring E Filling valve
G
D
B CO2 counterpressure
F Lower electropneumatic valve
G H
G Deflector H Air evacuation pipe
Hydra N The HYDRA-N filling valve: efficiency and hygiene The task of the filling valve is to transfer the correct quantity of product into the bottle, as quickly as possible, in the most hygienic manner possible and with the greatest possible precision, reducing maintenance and sanitisation needs to a minimum. The valve fitted on Hydra machines comes from a well tested technology available on the market, with important improvements applied by OCME as to reach an average speed of 375 ml per second (for 1.5 lt bottles). One of the great advantages provided by this level of performance is that 40 valves are sufficient on a machine that outputs 14,400 bph (1.5 l bottles); competitor solutions require many more filling heads, with the obvious disadvantage of a greater initial investment and higher maintenance expenses in the future. The incredible average filling speed (that in some installations is generally even being surpassed) is ensured thanks to the unique design of the valve, which
reduces turbulence during the filling stage. Mechanically speaking, the valve is very simple: it is composed of very few elements, has no dynamic gaskets (sliding during the opening-closing stage), drains perfectly (does not contain the usual 9 cc drop of liquid) and wear is practically non-existent. It has been designed specifically for highly hygienic filling. For still water filling, air is evacuated from the bottle through a separate pipe, with no risk of contaminating the main product tank. Parts coming into contact with the product may be manufactured in stainless steel 316 or in a special food grade rubber that is resistant to aggressive treatments (ex. ozonated water, hot CIP cycle, acid additives, etc.). Quick valve disassembly Disassembling the filling valves is extremely fast and easy; just loosen a screw by half a turn to remove two valves simultaneously.
F
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7 HYDRA I-AR Isobaric level filling valve with separated air return A B
C
D
A Upper electropneumatic valve B Separated air return channel
• Stage 1 Bottle lifting A mechanical cam lifts the bottle lifters and pushes the bottles towards the centring bell. The push force exerted by the bottle lifter allows the bottle to remain sealed on the valve.
E
• Stage 2 Bottle pressurisation and/or fluxing The bottle is then pressurised using CO2 by acting on the electronic control of the upper block so that the counterpressure chamber and the inside of the bottle to equalize.
F
C CO2 counter-pressure
G
D Tank E Spring F Filling valve
H I
G Lower electropneumatic valve H Deflector I Air evacuation pipe
• Stage 3 Filling The product begins to flow inside the bottle as soon as the bottle reaches the same pressure as the counter-pressure chamber (isobarometric condition). The air contained inside the bottle is evacuated through a tube on the lower part of the valve. Product flow is controlled by a deflector inserted in the external part of the tube, in order to avoid turbulence and foam which may be detrimental to proper filling. Filling is complete when the product level reaches the lower part of the tube, cutting off air return. • Stage 4 Closing Once filling is complete, an electronic signal enables closing of the block section dedicated to pressurisation. • Stage 5 Decompression The pressure inside the bottle is gently released through the lower block and evacuated through a centralised manifold.
Hydra I Isobarometric filler with electro-pneumatic control system The valve is designed in blocks with minimal parts, for extremely easy and limited maintenance interventions. The blocks are independent from one another, to facilitate disassembly and/or replacement. • The upper block comprises the electro-pneumatic drives that control pressurisation, filling and closing. • The central block comprises the valve body, with the spring, siphon, central stem and tubes for air return. • The lower block comprises the electro-pneumatic drives that control decompression (single or, on request, dual). The carbonated liquid filling stages, PLC-controlled by setting the specific recipes are summarised below:
• Stage 6 Bottle lifter lowers Once atmospheric pressure has been reached, the bottle is accompanied to the height of the starwheel for transfer to the capping machine. For format changeover, simply select a different recipe from the Operator Panel and, if necessary, substitute the tubes that regulate the level in the bottle.
Hydra I-AR Upon customer request, a separated air return may be added to eliminate any risk of contaminating the product in the tank. With this modification for non-carbonated products, filling will be carried out by gravity without the aid of a slight overpressure. The PLC controls the upper block for valve opening and closing without counter-pressure. In this case, stages 2 and 5 are completely eliminated, facilitating the use of lightweight, flat-bottomed preforms.
16 OCME: Filling systems in the beverages industry
Hydra N-V Hydra for spirits (slight negative pressure, for glass bottles)
At this point, the bottle lifter may lower and the bottle exits the filler.
Operating principle This machine derives from our Hydra filler for still liquids. The only variation required was the addition of a pneumatic actuator on the upper section of the tank that operates the “open-close� control for the air return pipe of every head. The bottles incoming to the filler are positioned on the disk of the bottle lifter which, once released from the cam, pushes them against the rubber seal and then, continuing its stroke, opens the liquid valve. Filling begins when the pneumatic actuator opens the air return, so that the slight negative pressure reaches the bottle. Once the bottle has been completely filled, the automatic-levelling stage begins, by detaching the bottle from the head by a few millimetres, thanks to the slight negative pressure. The filling cycle ends when the pneumatic actuator transmits the close command, while the flow of liquid is closed, detaching the bottle from the head.
Technical features The main feature of this filler is that it operates by means of a slight negative pressure that is applied to the tank, is transferred to the heads and reaches the bottle during the filling cycle. Slight negative pressure Note that the slight negative pressure in the tank and in all the parts involved in filling ensures that not a drop of product is wasted and, even more advantageous, allows for the automatic levelling at the end of the filling cycle, by suctioning the excess product from the bottle back into the tank. Level precision This filling method guarantees extremely precise levels, with sigma values even lower than 0.8 (always depending on the type of bottle being handled and the level positioning). Changing the level in the bottle The level position in the bottle may be changed without changing the tubes, within a 25 mm range (always depending on the type of bottle being handled and the level positioning). The level may be changed by changing the height at which the tank is positioned; as for all fillers that handle glass bottles, the tank is obviously motorised. Note that these levels for bottle filling may be automatically corrected also based on possible temperature differences during the day or, even more so, between summer and winter.
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8
HYDRA N-V Filling valve for gravity level filling with slight negative pressure.
D
Open-close pneumatic actuator on the air return This control closes the air return from the bottle during the standby stage between filler infeed and outfeed, not involved in the filling cycle. This device keeps large amounts of air from being sucked in from the environment and flowing into the tank through the tubes. This allows us the luxury of using electric aspirators with low air flows, hence reducing the loss of alcoholic content that may occur during the filling cycle. Siphoning inside the tank One of the unique characteristics of our still water valve is that it is siphon-free, that is to say, the body of the valve is immersed in the annular tank. This characteristic allows emptying the filler valves completely and sanitising the machine during all possible production and cleaning cycles (usually, with level fillers, a drop of un-drainable product, of about 9.5 cubic centimetres, always remains trapped in the siphon).
A
H B E
F C
Tilted tank bottom The tank bottom is tilted so as to avoid possible areas of un-drained liquid. The supply pipes are always fitted on a slight incline. All possible causes for product stagnation have been eliminated (gaps due to poorly positioned gaskets or inadequate designs). These characteristics, as a whole, make it possible to drain and sanitise the entire machine perfectly. Simplicity of the filling valve The filling valve is extremely simple and composed of minimal parts. A 5 mm stroke suffices to open the liquid and the air return, so wear on parts is extremely limited. Furthermore, there are no sliding gaskets (dynamic) that come into contact with the filling liquid. These features, taken as a whole, increase valve reliability and make the valve easy to sanitise without the need for frequent servicing.
G
A Slight negative pressure B Product tank C Filling tube D Pneumatic cylinder for valve activation E Moving bell F Sanitisation pipe G Pneumatic bottle lifter H Air-vacuum return pipe
18 OCME: Filling systems in the beverages industry
HYDRA M Flow meter filling valve
9
Hydra M
A C
B
G E
D F
A Flow meter B Product pipe C Tap actuating pneumatic cylinder D Sanitisation pipe E Plug F Bottle support G Rotating structure
Hydra-M This is a rotary filler with either a mass or magnetic flow meter. The filler may be fitted with from a minimum of 32 to a maximum of 120 valves. It is suited to filling bottles of any shape or volume, either glass or PET, with extreme volumetric precision. The production output ranges between 8000 bph to over 100,000 bph. This type of filler is used mainly in the beverages sector for all types of beverages, provided they are flat (not carbonated). If necessary, hot filling may be carried out (8590째) The filling cycle is wholly electronically controlled and the various stages may be programmed and are perfectly repeatable, based on the type of product, on the type of container, on the production speed and on the bottling temperature. The bottle is filled without coming into contact with the valve, thereby averting any damage to the machine in
the unfortunate case of bottle contamination. All machine parts that come into contact with the filling product are made of stainless steel Aisi 316, tilted, polished to a shine and joined without sharp edges or gaps. All this helps to avoid turbulence that may be created during the filling cycle and makes it possible to sanitise the entire machine. The limited movement of the stem-plug that opens the filling valves is protected by a special membrane, to avoid sliding parts coming into contact with the filling product. This device reduces wear and contributes to maximum hygiene. The false bottles used for closed-circuit washing, sanitising and disinfection, are completely automatic. The tilted base completely eliminates stagnation points and makes it easy to remove product or detergent residues, thereby improving the microbiological safety of the entire filling environment. The elements described above, along with other devices, among which the sterile housing for the entire filling system, allow for elevated hygiene standards, ideal for bottling in an aseptic environment.
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19
21 11
Features shared by all Hydra models The base: small-sized and functional In fillers, the base is a critical point in that, if it is poorly designed, it may favour the persistence and proliferation of contaminants. The base of the Hydra machines provides considerable functional and economic advantages. It is made of stainless steel and it tilted to allow for easy sanitising and avoid the creation of liquid stagnation points. Furthermore, thanks to a careful engineering study, it has been rationalised to reduce its complexity and, consequently, the cost of many devices connected to it. An additional result of its unique design is that the space that the machine occupies on the ground is less than that of other machines with the same number of filling heads. The tank The filler tank is the chamber where the liquid is accumulated before being transferred into the bottles. This is a critical point for cleaning and food safety. The tank of the Hydra machines is annular and made of stainless still. Instead, in Hydra M machines the tank is central. Thanks to the shape of the tank and the manufacturing materials, cleaning operations are easy and effective. Closed-circuit sanitization system In a food liquids filler, sanitising is of fundamental importance. For this reason, any contact between the atmosphere and hygienic cleaning solutions and between operators and machine parts must be avoided, starting from the moment the cleaning cycle is begun.
Figure 10 Closed-circuit sanitising system with false bottles.
The Hydra N, I and I-AR versions use a closedcircuit system with semi-automatic false bottles. The scope is to insert containers on every filling station (this stage is manual), run the sanitization cycle and allow the false bottles to drain automatically so as to avoid that the operator come into contact with the machine and thereby potentially contaminate the surrounding environment. The decision to use a semi-automatic system was dictated mostly by economic reasons, in that the cost of this type of system is approximately one tenth that of a wholly automatic solution. To the contrary, as regards the use of false bottles, in the wholly automatic mode there are interactions that are potentially hazardous in terms of food safety and, using the semiautomatic solution the operator work load is halved. Format changeover The plastic bottles are moved by the air conveyors directly to the infeed starwheel that holds the bottles by the neck. A special (patented) device controls the pitch of incoming bottles. No format change instruments are required (such as side screws or infeed starwheels) if the bottle neck size does not change. As for glass bottles, a patented quick-release system is used. This system does not require the use of tools or instruments.
Figure 11 Stainless steel annular tank.
20 OCME: Filling systems in the beverages industry
Libra R5: Electronic weight filler
T
his is a weight filler (weight with load cells) that ensures maximum precision in measuring the product poured into the bottle. These machines are manufactured with extreme care, especially for the electronic components. Before starting the filling cycle, the container tare weight is calculated; subsequently, the centrifugal force that may disturb weighing is taken into account, as is the supplementary weight caused by the impact of the liquid flowing into the bottle. Subsequent controls allow for the correction of systemic weighing errors. This machine may be used for any type of product, provided it is
still (non-carbonated). Exact weight calculation is ensured by a twoor three-stage filling function (coarse and fine fill) and guarantees excellent results even with difficult to handle products and containers. The machine also provides the added advantage of clean filling, as the container does not come into contact with the filling valve. The weighing technology also avoids the vertical movement of the container, hence eliminating undesirable wear and difficulties centring the filling valves. The quantity of product poured into the container is easy to parameterise in a wholly automatic manner, at any change in the filling temperature, which may be seasonal and in some cases even daily.
12
Figure 12 Rinser for 5 litre bottles
13
Figure 13 Double capping head for cap and cap insert placement
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22 OCME: Filling systems in the beverages industry
Libra R5 for spirits
e
lectronic weight filling for spirits and alcoholic products represents a good alternative to the traditional level filling system. Indeed, in the majority of cases in this sector, this means glass bottle filling that, due its natural conformation, may result in extremely variable volumes within the same batch of bottles. The electronic weight filling system ensures high-precision filling, thereby providing a considerable economic advantage in terms of the savings on volume of product at year’s end. A considerable advantage provided by the Libra machines is the possibility of mixing alcoholic products in the filler. This system can handle more than one product on the same machine, mixing the products directly at the filling point. The Libra filling nozzle for alcoholic products is designed to guarantee a perfect laminar flow; for this purpose, it is
designed to move downwards during the filling stage, as opposed to the typical upwards movement of other weight systems. Thanks to this feature, the Ocme valve can enter the container during the filling stage. Why use weight filling technology for alcoholic products? • Accurate filling thanks to precise weight calculation • Standard deviation of about 1 g on 1 litre bottles (subject to control) • No effect caused by temperature • Possibility of filling more products on the same machine and mixing directly in the filler • No product loss due to the use of vacuum • No mechanical lifter for bottles means less maintenance • No contact between the nozzle and the bottle.
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Libra R5 for 5 gallon bottles
T
his machine uses a weight filling system, which is indisputably the most precise system as compared to other filling technologies. The wide mouth of the 5-10 l containers is particularly suited to high-speed filling, often achieved using just a few filling heads. Moreover, there are the unquestionable advantages of clean filling, as the
container does not come into contact with the filling valve. The container does not need to be moved vertically, hence eliminating undesirable wear and difficulties centring the filling valves. Furthermore, the containers, which are always very light, do not require that the machine bear the axial load needed to enable tap opening, as is usually the case in traditional filling systems.
24 OCME: Filling systems in the beverages industry
Hygiene and safety for food products
e
very device used for the production and packaging of food products must meet high safety standards. The news media report a growing number of cases of food adulteration and as a result the general public is extremely sensitive to issues regarding the quality and safety of food products. For companies in the food industry, investing in safety is actually more of an opportunity than an expense, in that the risk of compromising the corporate image, not to mention of paying out huge sums for damages, weighs much more than the cost of equipping machines with avant-garde technology systems to comply with food hygiene and safety standards. Ocme has invested in this field, fitting its machines with
leading-edge sanitising devices and adopting all the construction measures required to avoid product contamination and health hazards. In place cleaning/sterilisation Ocme machines are built with particular care in the realisation of the cleaning and sterilisation cycles to be carried out in place. These periodic treatments are carried out by special CIP-SIP control units, which may be either manual or completely automatic. The automatic units allow the operator to automatically set the concentration and length of the cleaning-sterilisation cycle. In both cases, these are closed-circuit cycles to avoid wasting acid substances that must be disposed of accordingly.
14
Figure 14 Laminar flow system fitted with HEPA filters to keep the filling chamber at a slight pressure, keeping out dust particles.
Figure on the facing page The CIP system (Clean In Place) guarantees maximum hygiene, cleaning all parts that come into contact with the product in the filler.
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26 OCME: Filling systems in the beverages industry
15
Figure 15 Bottle lifting system for glass bottles
16
Figure 16 Bottle lifting system for PET bottles
17
Rinsing Rinsing and the treatment required to ensure container cleanliness before it is filled. This operation may be carried out using just water, with sterile air, or using special sterilisation products, depending on the results desired. Based on the solution requested, rinsing may be simply mechanical or, if active compounds are used (for example, hydrogen peroxide or ozonated water), a more thorough sanitization may be achieved. Positive pressure Usually, the filling tri-block (rinser-filler-capper) has an integral protection system, meaning that the whole assembly is separated from the outside environment. Special blowers that emit sterile air (obtained thanks to special HEPA filters) generate an environment with a slight positive pressure; therefore, air from the outside cannot enter the internal machine chambers. Tilted base This serves to avoid water stagnation or dirt deposits. It is easily cleaned and drainage is collected in a single position. Stainless steel AISI 316 L All parts that come into contact with the filling product are made of stainless steel and are polish-finished and free of pores or sharp edges. The internal surfaces that come into contact with the product are also tilted to avoid stagnation, so the whole machine is perfectly drainable.
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18
Cap treatment Additional hygienic treatments may be executed before applying the cap to the bottle. The machine may be fitted with UV lamps, ozonated water cleaning systems or dust aspiration systems.
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Inspection The containers are inspected after having been filled and capped, to analyse the contents against the presence of impurities. If impurities are found, the container is rejected. Bottle lifting system (jack) A truly efficient bottle lifting system (jack) has been designed for the Hydra level fillers. It works perfectly in all operating conditions, without giving any kind of trouble. The moving parts are so stable that wear on the bushings and gaskets is minimal. Thanks to system stability and sturdiness, the drive cams can be considerably titled, permitting to start the filling cycle at a very early stage in the filling carrousel. It may be used for both glass and PET containers, without requiring great modifications. The system can work at very high speeds (up to 100,000 bph) without requiring external lubrication, a considerable competitive advantage as compared to other similar systems on the market. The only lubrication required is for the compressed air that generates movement, without ever being discharged into the environment. This means being able to eliminate all traces of lubricant near and around the filling valves, thereby avoiding contamination hazards.
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Figures 17 and 18 Some examples of rinsers in monoblock configuration with the filler Figure 19 Valve detail Figure 20 Cap feeder
28 OCME: Filling systems in the beverages industry
The ideal plant in the beverages industry
F
illing, packaging, palletising and integrated logistics. Ocme provides turnkey solutions for complete lines in the beverages industry, thanks to over 50 years of experience working with the leading international companies in this sector. The enormous added value that Ocme offers companies in the beverages industry is the ability to give customers the opportunity to interface with experts specialised in this sector who can understand, implement and advise on strategic choices. Over the years Ocme know-how
Conveyors and logistics in beverages lines Belt conveyors for loose containers
Conveyors for bundles, crates and cases and cartons
Ocme designs and manufactures belt conveyors that provide the best possible dynamic flow of loose containers (full or empty) between the various filling, labelling, depalletising and packing machines. Ocme uses high-tech control systems to maximise speed and accumulation synchronicity. In this way, Ocme can ensure high performance levels with minimal downtime. All belt conveyors are modular in design and manufactured using stainless steel for the side frames and supports, to guarantee resistance in any food environment.
Ocme designs and manufactures conveyors that provide the best possible dynamic flow of packages between the various packing and palletising machines. Ocme uses high-tech control systems to maximise speed and accumulation synchronicity. In this way, Ocme can ensure high performance levels with minimal downtime. All conveyors are modular in design and designed and built taking into particular consideration the type of package to be conveyed. In particular, for film-only bundles, the conveyors are built using low-friction chains and short, tight-pitch passages, in order to be able to create multipack conveyor systems for small packs of film-only bundles.
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has permitted us to perfect our engineering techniques for packaging lines and reach extremely high levels of automation and efficiency. Ocme is capable of designing increasingly ergonomic and compact lines, reducing the number of operators required to run the line, to a minimum. The flow of materials (raw materials, finished product) is analysed in order to minimise warehouse stock, constantly ensuring the best supply to the system and guaranteeing product traceability. All of this is done without overlooking what perhaps the most important element, that is, the efficiency of the line, or rather, the line’s real warehouse output. Ocme-designed lines reach extremely high efficiency levels also thanks to reliable, high-automation machines. Currently, we are talking about results in excess of 90% per PET and 85% for glass-handling lines, as compared to rated output (guaranteed performance as per DIN 8782 standards). Ocme also obtains extremely high efficiency levels on extrafast lines (for example, 55,000 bph and 78,000 bph with PET formats).
Air conveyors for empty PET bottles
Pallet conveyors
Auriga laser guided vehicles
In terms of handling empty PET bottles, Ocme guarantees optimised system integration to ensure bottle transfer with minimal downtime and damage to lighter bottles. The fans are fitted with inverters to reduce energy consumption and excess pressure. If the line must handle different formats, a system for automatic body and neck guide changeover may be inserted. In this way, the operator may choose the various programmes to be managed directly from the operator panel.
Ocme designs and manufactures pallet conveyors for full and empty pallets that provide the best possible logistic flow of pallets along the system. These conveyors also comprise lifters, lowering devices, rotating tables and shuttle systems on rails. Ocme uses high-tech control systems to maximise speed and accumulation synchronicity. In this way, Ocme can ensure high performance levels with minimal downtime. All conveyors are modular and designed and built taking into particular consideration the type of package to be conveyed.
Of all the available technologies, laser-guided navigation is both the easiest to install and the one that provides greatest operating flexibility. Hence, OCME has chosen this solution to provide Auriga with a highly reliable drive and route correction system. Laser-guided navigation uses special reflective targets fitted to the walls of the shuttle working area, to provide a reference grid for shuttle orientation and steering. In fact, this type of system does not require the installation of any fixed or movable structures on the plant floor.
30 OCME: Filling systems in the beverages industry
Complementary machines for the filling line
T
hanks to its long-standing experience in the beverages sector, Ocme can provide customers with complete support for turnkey solutions. The main machines included on the beverages line are designed and manufactured by Ocme, providing a further guarantee of the highest quality standards and minimal integration difficulties. Ocme places entire teams of specialised engineers at the service of its customers to develop solutions that respond to specific bottling and handling needs. Each machine manufactured by Ocme and any integrated device manufactured by external suppliers are the result of accurate studies and a rigorous selection process, with the sole aim of guaranteeing that the performance demanded by each customer is fully met. Sagitta labeller Sagitta is the line of roll-fed labellers developed by Ocme to complete the range of beverage bottling lines offered. The machine can handle PET bottles with sizes varying from 0.33 to 3 litres and has been designed with particular attention to ergonomics, easy maintenance and handling. Further system flexibility is ensured by the possibility of using a wide range of glues and labels, in order to be able to adapt the machine to
any production requirement. Transfer of the label from the cutter to the transfer roller is synchronised, so that the label does not slip on the roller itself; in this way the OCME Sagitta machine is not dependent on the characteristics of the label and requires less maintenance for unit cleaning. The vacuum system has also been greatly simplified, guaranteeing greater component service life, greater reliability and greater ease of use. To accommodate the use of a variety of glue types in order to adapt to any production environment, the OCME Sagitta features include the possibility of regulating the amount of glue on the label and the temperature in each area of the system. Full access to all machine parts is guaranteed by the in-line positioning of labelling unit components, the compactness of the machine and the limited number of components fitted under the machine base. As a result, format change and maintenance operations are fast and simple. A single system with three brushless servo-drives controls machine speed, labelling group speed and label unwinding, guaranteeing the perfect synchronisation of the various components. Moreover, there is no need to phase any machine component for format change, making this operation faster and more repeatable.
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Figure 21 Sagitta roll fed labeller.
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Dorado and Antares Depalletisers
Vega shrink-wrap packers
Altair wrap-around packers
Dorado and Antares are the names that designate OCME’s line of depalletisers. Dorado models are low or high level depalletisers specifically designed to handle loose containers such as jars, tin cans and bottles with an output speed between 2 and 7 layers/minute. Layer transfer takes place by means of a rotating pusher or a self-adjusting gripper head. Antares models are low or high level depalletisers specifically designed to handle secondary containers such as plastic crates, cartons and pails with an output speed between 4 and 15 layers/minute. Layer transfer takes place by means of a gripping head.
Vega is the line of shrink-wrap packers specifically designed to package bottles, flasks, jars, tins cans, multipacks, etc. in film only, film and layer pad and film and tray configurations, with output speeds ranging from 20 to 450 bundles/minute. The line of Vega shrink-wrap packers is subdivided into 3 subgroups with different features, based on the output capacity required. Each category of machine may process the following types of packages:
OCME wrap-around packers represent excellence in global secondary carton packaging systems. Different models are available for speeds ranging from 20 to 100 cartons per minute, handling containers such as bottles, cans, jars, tins and multipacks. As a complement to standard models, versions complete with the insertion of partitions, either traditional or pre-formed, are also available.
Perseus and Orion Palletisers
Pegasus Robot Palletiser
Manipulator layer forming system
Perseus is the line of palletisers with 90° infeed used to handle packs such as bundles, cartons, crates multipack, drums, etc. with output speeds of between 3 and 7 layers/minute.
Pegasus is the line of robot palletisers with multiple gripping system or layer grippers designed to pick up and entire layer of packs, used to handle packs such as bundles, cartons, crates, multipacks, drums, etc. with output speeds of up to 12 cycles/minute.
This system was designed to form layers upstream of traditional or robotic palletisers. Three functions have been integrated into one system:
Orion is the line of palletisers with in-line infeed used to handle packs such as bundles, cartons, crates, multipacks, pails, etc., with output speeds ranging between 5 and 9 layers/minute.
• film only bundles • film + layer pad bundles • film+ tray bundles • film+ U-board bundles
• Package turning • Layer forming • Layer compacting
32 OCME: Filling systems in the beverages industry
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The marketing value of filling machines
A
s it constitutes the heart of a filling line, the filler can greatly impact upon a company’s production and commercial output and potential. For companies in the beverages sector, the marketing division, as the lead player and primary driver for innovation, requires that the entire production division meet flexibility requirements geared at giving the company a competitive edge vis-à-vis, first and foremost, distribution and, secondly, the end consumer. The beverages sector is affected by various trends, some of which are the result of changes in consumer purchasing habits, while others are associated to distribution requirements. For example, the trend towards increasingly lighter packages (both bottles and secondary packaging) is appreciated by many consumers and distributors; for their part, companies in the beverages industry can leverage the fact that new-generation machines and lines are capable of handling fragile and unstable containers with greater ease, to emphasise corporate awareness regarding environmental and energy saving issues. Moreover, let us not forget that container shape is also an important element of differentiation: the fewer the limits imposed on designer creativity (especially those deriving from technical obstacles pertaining to production lines), the greater the opportunities to be seized from a commercial point of view. And that is not all. Safety, be it food safety or plant operator safety, is an increasingly topical issue. Here again, the marketing division of a beverages company may “sell” the safety level of its systems as an “ethical advantage” of its work policy. Substantially, the role of production technology should be viewed not only in terms of a technical platform, but also as a vehicle to transmit values, through the values chain, right to the end consumer. The extent to which this may be possible depends on the extent to which the production technology guarantees high standards in terms of efficiency and repeatability.
34 OCME: Filling systems in the beverages industry
Environmental respect
N
owadays, protecting and caring for the environment, for persons and for everything that surrounds us are fundamental aspects of corporate choices. Companies cannot afford to ignore issues such as environmental impact and industrial safety, neither in the organisation of production, nor in terms of products. For this reason, OCME tri-block filling systems and all other integrated systems and equipment for complete beverages lines meet the growing demand for reduced environmental impact and energy savings. On this matter, one of the most important features of new-generation fillers and palletisers is the capacity to handle lighter containers with greater ease, reducing impact stress and friction. Less packing material means an immediate saving on raw materials and, on the whole, less waste to be disposed of for the general community. The use of every process fluid, from rinsing solutions to the use of ozone to treat containers and capsules, is optimised to reduce or eliminate discharge outside production sites and guarantee rational, waste-free use. Furthermore, new shrink-wrapper ovens are designed to guarantee more than 20% energy
savings as compared to older ovens. One new-generation Vega shrink-wrapper alone guarantees savings of up to 30,000 Euro of motive power per year and over 75 tons of CO2 emissions (generally required to produce energy savings). Altair wrap-around packers are designed to use the least possible amount of glue while still guaranteeing sturdy, “logistics-proof� packs; this means less energy required to keep the glue at the right temperature and less material used on every carton. OCME has been committed for several years to the OCME WorldCare project, a corporate plan aimed at education and proactive intervention in environmental protection issues, through segregated waste collection and the careful use of energy and raw materials in general. The principles of the project focus on raising the awareness of design engineers around issues such as environmental protection and dwindling resources. The aim is to make new series of machines and systems with performance levels that can be made to grow hand in hand with the capacity to guarantee ecologically sustainable development.
Corporate environmental respect programme
All rights reserved. All registered trademarks mentioned herein belong to their rightful owners. OCME declines any and all responsibility for the contents of this document insofar as technical data, characteristics and descriptions may vary without advance notice. OCME is not in any way liable for damages deriving from omissions or inaccurate information contained in this document.
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All the OCME technologies dedicated to your sector
One of the characteristics for which OCME is renowned for in the market is the company’s flexible approach to customer needs. We believe that each sector must be followed with specific care, because each has specific needs. For this reason, our staff of professionals is specialised in responding to the needs of every single customer, based on the unique characteristics of each sector.
Beer Mineral water Soft-drinks Wines and spirits Food Edible oils Tissue Petrochemicals Pharmaceuticals Products for personal and home care
OCME UK Ltd. King John House, Kingsclere Park Kingsclere - Newbury Berkshire RG20 4SW (UK) Phone: +44-1635-298171 Fax : +44-1635-297936 e-mail: sales@ocme.co.uk OCME AMERICA CORPORATION 5300 N.W. 33rd Avenue, Suite 105 Ft. Lauderdale, FL 33309 Phone: 954-318-7446 Fax: 954-634-0238 e-mail: info@ocmeusa.com
The aim of this publication is to present our experience and our technologies, as applied to complete lines for the beverages sector. As for all OCME products, the systems and equipment devices and the services provided by our Company for the duration of the system’s service life, are designed to work at high production output, providing customers with sound support in the strategies choices to be implemented. Today, companies in the beverages sector have an incredible opportunity to differentiate and increase their competitive edge, aiming at efficiency and the integrated automation of the production plant, from filling right to handling pallets by means of laser guided vehicles; all of this, thanks to OCME technology.
OCME FRANCE 42 avenue Montaigne 75008 Paris Phone:+33 (0) 6 27.89.36.20 email: commercial@ocme.fr OCME Packaging Equipment (Jiaxing) No.289 Mu Yang Road, Jiaxing Economic Development Zone, 314033 Jiaxing City, Zhejiang Province, P.R.China Phone: +86-573-83971680 Fax: +86-573-83971690 E-mail: info@ocme.cn OCMEXICO Embalaje, S. de R.L. de C.V. Homero 425 Desp. 2, Torre “B” Col.Chapultepec Morales México D.F., CP 11570 Phone: +52-55 52542401 ext. 103 Fax: +52-55 52542401 ext. 106 e-mail: info@ocme.com.mx
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OCME S.r.l. Via del Popolo, 20/A 43122 Parma (Italy) Phone +39-0521-275111 Fax +39-0521-272924 e-mail: info@ocme.it
Our task, as suppliers of packaging, filling and logistics technologies, is not just to install a system, simply providing a solution for an immediate problem. Rather, we believe that our job is to supply a vision of the future of production in the packaging and to produce solutions that are ahead of their time. At least, this is what we have been doing since 1954.
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OCME and filling systems in the beverages industry
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