Hot filling technology: “Liquid filling at room temperature is easier because the contact area of ​​the material does not change with the temperature difference of the material, and it is constant in terms of filling accuracy and filling speed. However, there are many uncertainties in practice. Material media, sometimes they have a relatively high temperature, so that the equipment will have a certain expansion ratio, which is taken into consideration at the beginning of the equipment design, so that the equipment has a certain elasticity. This is called mechanical manufacturing: "Pre-design method". Predict this situation in advance and make specific changes. Another is that the material starts to be hot, but it will slowly cool down during the filling process, and the beginning is low temperature, in the filling process. The temperature will rise slowly again. These conditions are difficult to solve by the filling equipment itself. This relies on some auxiliary equipment to complete the filling process, such as the constant temperature tank, the application of the heat preservation tank, so that the material can be filled in the specific Maintain a certain temperature difference within the time, not too large and undulating, resulting in unstable filling. This is called "auxiliary peripheral design method" in mechanical manufacturing. Although there are two Mechanical manufacturing theory, but to fundamentally solve the problem of hot filling accuracy and speed, more advanced scientific theories and design methods are needed. Swift Machinery is relying on the "first design method" and "auxiliary peripheral design method" to develop More comprehensive filling of mechanical products.
Hot Filling Technology Application: Application of PET Bottled Beverage Medium Warm Filling Technology in High Speed ​​Production Line
Since the birth of the warm filling technology in PET bottled beverages in China, the filling production line using this technology has matured in just a few years and has formed a certain market scale. The technology is based on the temperature limit of ordinary PET bottles. Through the matching filling production line, filling environment and subsequent processes, the product preservation is achieved without adding any preservatives. Through production practice, it has been shown that the beverages produced by non-heat-resistant PET bottles have reached the sanitary technical indicators of heat-resistant PET bottled beverages and the relevant national standards. The shelf life of the products has reached more than one year. The technology relies on rational filling system design, perfect packaging disinfection system and air purification system, comprehensive and thoughtful SIP system and CIP system as well as perfect production quality control management.
With the rapid development of China's beverage industry, the development of high-temperature filling production lines for PET bottled beverages has become inevitable. Achieving the high speed of the warm filling production line in PET bottled beverages is not a simple device amplification. Compared with the previous medium and low speed production lines, it is necessary to innovate and break through the empty bottle sterilization before filling and the inverted bottle sterilization process and equipment after filling. After several years of unremitting research and exploration, the PET bottled beverage medium-temperature filling production line has made a breakthrough leap in achieving high-speed, and the whole-line equipment level is close to the current world advanced level.
1. The empty bottle sterilization of the medium and low speed production line adopts the conservative disinfection liquid infusion, maintenance and dumping mode. This mode has many equipment links and large area, which is not suitable for the high speed of the production line. It is necessary to optimize the sterilization process of the empty bottle and simplify the sterilization equipment to meet the requirements of high speed of the production line. To this end, Jiangsu Xinmeixing has cooperated with internationally renowned disinfectant production companies to replace the disinfectant used in the early days with a safer and more efficient disinfectant, which has changed the sterilization process of the original packaging materials (bottles and caps). That is, the original disinfectant is filled, maintained, and dumped into a disinfectant spray method. The empty bottle is sterilized by inserting the nozzle into the bottle mouth to move the spray disinfectant, and equipped with a high-efficiency spray nozzle imported from the United States. The sterilization is thorough and safe. At the same time, the consumption of the disinfectant of the equipment is greatly reduced, which is only 1/3 of the original process consumption, and has the advantage of greatly saving operating costs. It simplifies the sterilization equipment for packaging materials, reduces the equipment footprint, and most importantly, is more suitable for high-speed medium-temperature hot filling production lines. In addition, the sterilization of the bottle is carried out in a closed environment, the microorganisms are easily controlled, and the operating environment is sufficiently improved. It is easier to collect and treat the exhaust gas, which is beneficial to the environment and protects the operator from the disinfectant.
2. The inverted bottle sterilization of the low- and medium-speed production line adopts the method of the mesh chain conveyor belt with a long pouring time. This method covers a large area and needs to be supplemented with artificial righting bottles, which is not suitable for the automation and high speed of the production line. In order to meet the requirements of high-speed production line, our company borrowed and adopted the inverted bottle sterilization chain mode of high-temperature filling production line. At the same time, in order to meet the sterilization time requirements of the cap, the spray cooler is designed as a spray sterilizer to compensate for the lack of sterilization time of the bottle, so that the product can be fully sterilized before cooling.
In addition, the key equipment of the entire production line (empty bottle sterilizing, rinsing, filling and capping five-in-one machine) has the following characteristics:
1. Adopting the direct feeding technology of the air feeding channel and the bottle entering wheel, the bottle setting wheel adopts the innovative design of the bottle mouth clamping mechanism with the bottle dividing function, which eliminates the bottle screw and the conveyor chain, and the bottle shape does not need to be replaced. Adjust any part.
2, the bottle transmission all adopts the card bottleneck technology, and replaces the traditional dial wheel with the bottle bottle bottle clip. The bottle shape does not need to adjust the height of the device, and there is no need to replace and adjust any parts.
3. The specially designed all-stainless steel rinsing clamp is strong and durable, and does not touch the threaded part of the bottle mouth to avoid secondary pollution of the bottle mouth. The disinfectant and sterile water flushing lines are equipped with pressure detection switches and have low voltage protection.
4, UHT and filling machine direct connection to reduce pollution. The feeding mode is that the main liquid pipe is connected to the distributor through the dynamic and static sealing, and the cylinderless structure is adopted. The filling machine is equipped with a CIP cleaning cup, which can make the CIP cleaning and SIP sterilization of the inner and outer walls of the filling valve in contact with the material.
5. Disinfectant rinsing machine, sterile water rinsing machine, filling machine, capping machine, transition wheel and other rotating parts and non-rotating parts are sealed by liquid tank to effectively protect carbon steel parts such as bearings. Corroded by the disinfectant. At the same time, it insulates the unclean air from the outside and maintains a clean filling environment.
6, equipped with a hundred-level air purification system and isolation window, and a clean air curtain at the inlet and outlet to prevent dirty air from entering the clean room. There are multiple isolation gloves on the window for easy maintenance. Equipped with equipment surface spray sterilization and clean room fumigation system.
After several years of painstaking efforts, tea beverages, juice drinks and functional beverages have become stable and mature products in the beverage market. Although aseptic cold filling technology can show its huge advantages in reducing costs in the tea beverage and juice beverage markets, However, its high equipment investment and equipment maintenance costs have made many companies discouraged. Nowadays, high-speed medium-temperature hot filling technology provides the best solution for many beverage companies, which not only meets the growth rate and safety of products, but also reduces the cost of packaging materials and operating costs for beverage companies. With the maturity of high-speed medium-temperature hot filling technology, it will provide more advanced, stable and reliable beverage filling equipment for more domestic large and medium-sized beverage manufacturers, bringing more direct cost benefits.
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