UltraClean En

Krones UltraClean systemsBottling lines for ESL and EHF products

They taste good whether still or spar-kling. Some are technically challeng-ing, others rather uncomplicated. Some feel at home in PET containers and others are better in glass bottles or cans: The variety of beverage types avail-able is huge – and, when combined with the different container types available, the diversity is practical-ly endless. Krones filling technolo-gy treats each of these options in the best way possible. For it comprises a large selection of filling methods, outputs and levels of hygiene. Simply select the system which is tailored to suit your requirements.

Krones filling technologyEquipped for every task

Can

Glass

PET

HDPE

PE

Hotfill

A filling line is not a casino: Uncer-tainties and leaving things to chance are never an option. This applies in particular to microbiological safe-ty. With the Krones UltraClean you are always on the safe side through-out the entire process. For the hygien-ic procedures guarantee a protective atmosphere, one which protects the product and also the consumer from risks and germs. The UltraClean creates safe filling conditions for

■ Sensitive soft drinks which do not contain preservatives.

■ Beverages which must be distrib-uted in a cold chain.

Reliable filling without preservatives UltraClean procedure with precise fit

The conventional concept:UltraClean filling with rinser technology

■ Peracetic rinser ■ Filling in the clean room ■ Bottle conveyance

with neck handling or base handling

Krones UltraClean filling process

UltraClean filling with Contipure and isolator ■ H2O2 preform sterilisation system Contipure ■ Contiform 3 stretch blow moulder ■ Isolator design ■ Own CIP module

The well-proven solution:UltraClean filling with Contipure and clean room

■ H2O2 preform sterilisation system Contipure

■ Filling in the clean room ■ Bottle conveyance with

neck handling

The glass variant: UltraClean filling for premium products

■ Individually adapted solutions

■ Optimised environment conditions around the line

■ Hygienically designed container conveyance on demand

As individual as your product: Depending on the requirement, we will establish a suitable UltraClean concept with you

Taking measures for the correct positionEspecially with sensitive bev-erages, the products and the production must fit together down to the last detail. There-fore, there is no prepared tem-plate when we design your per-sonal UltraClean system. On the contrary: Together with you, our experts create an individual pat-tern which put all relevant fac-tors into consideration – start-ing with the properties of your product to the processes in your plant and all the way to the basic conditions at your site. This way, you will receive a line that is as individual as your product.

Future-oriented, clever and safe

UltraClean for special cases

General characteristics ■ Suitable for ESL and EHF products ■ Processing of beverages containing

particles possible ■ Preform sterilisation via gaseous

H2O2 ■ Isolator design ■ Continuous production time of ap-

prox. 72 hours

Future-oriented, clever and safeUltraClean filling with Contipure and isolator

Contipure preform sterilisation ■ Treats preforms with gaseous H2O2 ■ Simultaneously sterilises the in-

side and outside of the preform ■ Effective sterilisation guaranteed

via dry process ■ Change-over times are thus re-

duced to a minimum

Cap sterilisation system ■ Treats preforms with gaseous H2O2 ■ Can be equipped with cap inspec-

tion system according to require-ments

Filler ■ Ensures microbiological safety

through Krones well-proven isolator design

■ Separates moving parts from rotating part via liquid barriers

■ Determines the filling quantity ex-actly by flow sensors or load cells

■ Is equipped with its own CIP mod-ule

■ With the Volumetic VFJ-D variant, it also gently fills particles with a size of up to 8 x 8 x 8 mm

Capper ■ Processes different cap types ■ Monitors each individual capping

process ■ Every capping head driven with its

own servomotor ■ Omission of electronic compo-

nents within the isolator and drives

High safety with low use of media: Contipure preform sterilisation

When is UltraClean filling with Contipure the right choice?When you are looking for a solution which …

■ guarantees biological safety for ESL and EHF products.

■ has low energy and media consumption.

■ can be cleaned quickly and efficiently.

■ has high operational reliability. ■ can also be used with bever-

ages containing particles.

UltraClean filling with Contipure and isolatorBenefits to you

No water, high microbiological safetyDuring production, the entire system consumes not a single drop of liquid. This lowers the overall water con-sumption while simultaneously rais-ing the level of microbiological safety.

Reduced to the essentialThe system does without any addi-tional peripheral equipment such as chemicals preparation and sterile water creation, and uses a single con-troller for all the aseptic processes. This makes the system easy to service and operate.

Sterilising bottles? No need!Rather than wait to sterilise the fin-ished bottles, the Contiform gets to work already on their preforms. The module’s route is extremely effective. Fact is: preforms are more even and smaller by a multiple. This means: less work effort for the Contipure and less costs for you.

Characteristics ■ Individually designed Krones

rinser technology ■ Filling in the conventional clean

room ■ Bottle conveyance with neck han-

dling or base handling ■ Suitable for PET and HDPE con-

tainers ■ Disinfection of UV treatment of

caps ■ Capper with servodrive or mechan-

ical drive

UltraClean filling for special casesThe classical concept with rinser technology

When is the UltraClean filling with rinser technology the right choice?When you are looking for a hygienic filling system which …

■ covers a wide range of contain-ers and hygiene levels.

■ offers you a lot of room for in-dividual solutions.

■ combines proven technology with inexpensive prices.

■ is suitable both for HDPE and PET containers.

■ provides a continuously high performance over a long pe-riod of time.

■ consists of highly efficient components.

■ is based on Krones know-how.

Everything is possibleThe conventional UltraClean con-cept offers a lot of room for individu-al design: From rinsing with ionised air via three-channel rinser to the jet process where two media are applied simultaneously. There is the suitable technology for each product and each hygiene level.

Characteristics ■ H2O2 preform sterilisation system

Contipure ■ Filling in the conventional clean

room ■ Bottle conveyance with neck han-

dling ■ Disinfection or UV treatment of

caps ■ Capper with servodrive or mechan-

ical drive

UltraClean filling for special casesThe classical solution with Contipure and clean room

When is the UltraClean filling with Contipure and clean room the right choice?When you are looking for a hygienic filling system which …

■ is focussed on future-oriented technology and keeps cost in mind at the same time.

■ puts sustainability into consid-eration and stays for low media consumption.

■ securely sterilises packaging material and keeps residues low at the same time.

■ consists of highly efficient components.

■ is based on Krones know-how.

Sterilising bottles? No need!Rather than wait to sterilise the fin-ished bottles, the Contiform gets to work already on its preforms. The module’s route is extremely effective. Fact is: preforms are more even and smaller by a multiple. This means: less work effort for the Contipure and less costs for you.

High-tech which pays offInnovative or well-proven? This solu-tion makes your decisions easier. Because it combines future-oriented sterilisation methods with the clas-sical clean room. This is precisely the equipment you need to produce at a high level combined with costs that do not exceed.

UltraClean filling for special casesThe glass variant for premium products

Characteristics ■ Individually adapted solutions that

ensure beverage stability ■ Krones rinser technology accord-

ing to requirements ■ Filling in low-germ environment ■ Container conveyors in hygienic

design ■ Different options for cap treat-

ment, e.g. dry and wet disinfection ■ Capper in hygienic design ■ Optimised environment conditions

around the line

When is the UltraClean filling for glass the right choice?When you are looking for a hygienic filling system which …

■ fills premium products safely in glass containers without the use of preservatives.

■ establishes new ways in filling ■ is operated very economically

efficient. ■ provides continuously high

performance over a long period of time.

■ consists of high quality components.

■ is based on Krones know-how.

Do you need something special?Premium products accept no faults. Therefore, the Krones UltraClean variants put emphasis on three unbeatable factors for success: indi-vidual planning, high-quality compo-nents and overall Krones know-how ranging from the bottle washer all the way to the capper.

Filling systems: Modulfill Asept VFJ The aseptic specialist with flow meter

Method of operationAs soon as the PET container is cen-tred below the valve, the filling pro-cess commences. Two different fill-ing speeds guarantee optimum flow. The inflowing liquid quantity is mon-itored by an inductive flow meter. The valve closes once the exact filling quantity has been reached.

Characteristics ■ Precise measuring of fill quantity

via inductive flow meter ■ High microbiological safety

through non-contact filling ■ Guarantees reliable process by

feeding the product from above with steamlocked sliding ring manifolds

■ Quick and energy-saving sterilisa-tion of the valves using steam

■ Short stoppage times thanks to parallel cleaning of the product route and the isolator

When is the Modulfill Asept VFJ the right choice?When you are looking for a filling system which …

■ ensures exact fill quantities. ■ offers high microbiological

safety. ■ treats the product gently. ■ is quickly to clean with little

energy used.

All good things come from aboveIn order to reduce product loss to a minimum, the product to be filled is fed into the machine from top. The sliding ring manifold takes care of the feed and provides faultless hygienic conditions by means of a steam lock.

Quicker and less expensive with steamBecause the product is sterilised with steam in stead of hot water, the sys-tem can be connected directly to the steam supply. The intermediate step with sterile water UHT is therefore completely omitted just like the time and cost effort in this connection.

VFJ = Volumetric filling, Flow meter, Full Jet

■ Perfect flow thanks to two filling speeds

■ Turbulence-free switching over of the speeds using solenoid valve technology

■ Cleaning with open SIP cup to the isolator, no CIP return channel and no bottom manifold required

■ Steam sterilisation of product channel with closed SIP cup, monitoring via steam discharge via stationary pressure sensor

■ Hygienic design ■ Electro-pneumatically controlled

filling valve functions

Filling systems: Modulfill Asept NWJ Exact filling weight with each product

Method of operationThe PET container is centred below the valve and weighed using load cells. Once the empty weight is deter-mined, the filling valve opens and fill-ing begins.Two different filling speeds guarantee optimum flow. During filling, the load cell checks the incoming liquid flow.

Characteristics ■ Precise measuring of fill quantity

via load cells ■ High microbiological safety

through contact-free filling ■ Guarantees reliable process by

feeding the product from above with steamlocked sliding ring manifolds

■ Quick and energy-saving sterilisa-tion of the valves using steam

■ Short stoppage times thanks to parallel cleaning of the product route and the isolator

■ Perfect flow thanks to two filling speeds

■ Turbulence-free switching over of the speeds using solenoid valve technology

■ Cleaning in the closed system by using automatic CIP cups

■ Hygienic design ■ Electro-pneumatically controlled

filling valve functions

All good things come from aboveIn order to reduce product loss to a minimum, the product to be filled is fed into the machine from top. The sliding ring manifold takes care of the feed and provides faultless hygienic conditions by means of a steam lock.

Quicker and less expensive with steamBecause the product is sterilised with steam in stead of hot water, the system can be connected direct-ly to the steam supply. The interme-diate step with sterile water UHT is therefore completely omitted just like the time and cost effort in con-nection with this.

Onto the weighing systemThe valves of the Modulfill Asept NWJ is equipped with load cells. This way, the system achieves precise filling quantities for each product independently from its properties.

When is the Modulfill Asept NWJ the right choice ?When you are looking for a filling system which …

■ guarantees absolutely precise filling quantities for products with different properties.

■ offers high microbiological safety.

■ treats the product gently. ■ is quickly to clean with little

energy used.

NWJ = Net weight filling, Weighing cell, Full Jet

The valve closes once the exact fill-ing quantity has been reached. After a short settling phase, the weight is checked one more time and the filled product leaves the machine.

Filling systems: Modulfill Asept VFJ-DThe specialist for beverages containing particles

Method of operationThe system firstly feeds the particles into the filling valve and then fills particles and juice at the same time: First the liquid product reaches the valve stem via a product pipe and then the particles are added via a separate pipe. When doing so, an inductive flow meter measures the volume of the product displaced in the filling valve thus allowing the quantity of particles to be precisely calculat-ed. Once the filling valve opens, particles and juice flow into the PET container centred below. The valve closes once the exact filling quantity has been reached.

Characteristics ■ Short changeover times and maximum safety for the

particles via simultaneous filling of both components ■ High microbiological safety through non-contact filling ■ Precise measuring of fill quantity via inductive flow

meter ■ Guarantees reliable process by feeding the product

from above with steamlocked sliding ring manifolds ■ Quick and energy-saving sterilisation of the product

channels using steam ■ Short stoppage times thanks to parallel cleaning of the

product route and the isolator ■ Perfect flow thanks to two filling speeds ■ Turbulence-free switching over of the speeds using so-

lenoid valve technology ■ Cleaning in the closed system by using automatic CIP

cups ■ Hygienic design ■ Electro-pneumatically controlled filling valve functions

One valve, two flows, three advantages Juice and particles enter the filler via two separate pipes. Only in the valve the two flows are joined and filled together. This sophisticated method makes the Modulfill Asept VFJ-D three times a leader. Because it guarantees:

■ Short filling times ■ Precise filling quantities without expensive overdos-

ing of particles ■ Gentle treatment of the sensitive fruit pieces

Taken care of right from the beginning:Beverages with fruit particles do not only want to be filled gently, but they also need to be prepared in a gently way. Therefore Krones has developed the twin-flow process – an overall lines comprising all steps from production to filling. The clever thing about this: This line processes juice and particles separately from each other. For this is the only way to ensure that each component receives precise-ly the treatment it needs.

Good to knowModulfill Asept VFJ-D is also suitable for adding flavour components and it can be operated even if the particle dosing unit is turned off.

VFJ-D = Volumetric filling, Flow meter, Full Jet, Double filling valve

When is the Modulfill Asept VFJ-D the right choice?When you are looking for a filling system which …

■ does juice with fruit pieces of up to 8 mm edge length precisely and without loss.

■ treats the product gently. ■ offers high microbiological

safety. ■ is quickly to clean with little

energy used.

1 Product tank2 Inductive flow meter3 Switching valve fast/slow4 Product discharge valve5 Control cylinder, valve stem6 Valve stem7 Control cylinder, dosing

stem

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VFS = Volumetric filling, Flow meter, Short tube

Filling systems: Modulfill VFSFor carbonated and non-carbonated products

1 Tubular ring bowl2 Control cylinder, liquid valve3 Pressurisation and and return gas valve4 Switching valve fast/slow5 Snifiting valve, head space6 Snifting and CIP return channel7 Pressurisation and CIP return channel

Method of operationThe PET container is first pressed to the valve and weighed using load cells. Two different filling speeds guarantee optimum flow. The inflowing liquid quantity is monitored by an inductive flow meter. The valve closes once the exact filling quantity has been reached.

Characteristics ■ Precise determination of fill quantity via inductive flow

meter ■ Micro-biological safety by filling in multi-chamber

principle with separate return gas discharge ■ Perfect flow thanks to two filling speeds ■ Low-foam and low-turbulence filling via swirl insert in

the valve ■ Cleaning in the closed system by using automatic

CIP cups ■ Hygienic design ■ Electro-pneumatically controlled filling valve functions

When is the Modulfill VFS the right choice?When you are looking for a filling system which …

■ operates hygienically. ■ fills with low generation of

foam and gently. ■ ensures exact fill quantities.

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IT solutions

The SitePilot modular system con-tains IT solutions which we devel-oped especially for the beverage and food industry. Whether you wish to increase the utilisation of your line capacity, monitor your product qual-ity, or make spare parts handling more efficient: With SitePilot, you will always get the best result.

Lifecycle Service

Your company is unique – so why be satisfied with conventional solutions? Krones Lifecycle Service will support you and your production even after the purchase of new machines. These are services which are individually tailor-made to suit your products and location.

Krones Service Line

Do you need help with a technical problem? Or do you have an urgent question about your line? No prob-lem: We are just a call away. Just dial +49 9401 708090 for quick and straightforward assistance – in sever-al languages, around the clock!

enviro

High-performance technology with low consumption of resources and safety for humans and the environ-ment – this is all guaranteed by the enviro sign. TÜV SÜD (technical con-trol board), as an impartial appraiser, has confirmed: the enviro procedure leads to energy-efficient, media-effi-cient and environmentally compati-ble machines and lines.

Krones Academy

Turn your colleagues into high per-formers: The training courses pro-vided by the Krones Academy give you first-hand, practice-proven trade information. You will find the tailored know-how package for practically any field and hierachy level, ranging from technical courses to management training.

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krones agBöhmerwaldstraße 593073 NeutraublingGermany

Phone +49 9401 70-0Fax +49 9401 70-2488E-mail [email protected] www.krones.com