New atmosphere of the hottest aseptic filling fiel

2022-07-24
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New weather in the field of aseptic filling

more and more beverages, such as juice, non carbonated beverages, iced tea, coffee, sports drinks, purified water, pasteurized milk, must maintain good antibacterial properties during the filling process. In recent years, more and more PET bottles, PP bottles or HDPE bottles are used as containers for these drinks. Some experts predict that in the next few years, the PET bottle aseptic filling market will increase at twice the current rate

aseptic filling of plastic bottles must include the sterilization process of contents, bottle body and bottle cap respectively, and at the same time, the three should be combined in a sterile environment. The disinfection of contents is usually carried out in a short time of high temperature environment. The sterilized bottle cap can be made of multi-layer materials, or it can be a screw cap with plastic. Usually, the disinfection method of disinfection pool or UV sterilization is adopted

if the enterprise chooses aseptic filling, it means that it has to invest a lot of money in the whole disinfection system, and the disinfection and flushing systems must be combined. In this series of links, how to keep the team using different multi block polymers as adhesives to weld two plastic strips together in the process from disinfection to aseptic packaging is the most important issue for all enterprises. With the recognition of the importance of asepsis and anti-virus for products, different asepsis methods have emerged

at present, we are familiar with two sterilization methods - wet sterilization with acid and dry sterilization with hydrogen peroxide (hydrogen peroxide). Both of them show their own characteristics in terms of efficiency and safety. At present, most of the sterilization methods used in aseptic cold filling technology in the world are wet sterilization, but a big problem in wet sterilization is that the pasteurization water ensures that the viscosity is not warped; When cleaning the packaging bottle, it is bound to be polluted, and the sterilized water is seriously polluted by the sterilization medium, so measures need to be taken to drain and treat it, which will have a serious impact on the environment. The emergence of dry valve aseptic cold filling technology solves this problem well

khs interprets dry valve aseptic cold filling technology

khs launched the filling system corresponding to these two processing methods at the Drinktec exhibition. KHS company introduced that some of its customers prefer to choose KHS alfill dry sterilization system at present, mainly considering the cost savings, while others are more confident about the traditional bottle and cap disinfection methods

khs alfill online filling room adopts micro insulator, which can reach the cleanliness standard of class 100. The size of sterile area has been reduced, and only a few independent areas are sterile areas: PET bottle guide rail part at the sterilizer, valve part at the filling machine and capping part. The production range is from 3000/h to 50000/h

the emergence of dry valve aseptic cold filling technology solves the problem of environmental pollution.

wet aseptic technology is to wash the sterile medium with sterile water after sterilizing the bottle. In this process, the sterilized water will naturally be polluted by the bacteria medium without steel. The polluted water will pollute the environment when it enters the water treatment system. However, the dry valve technology of KHS does not need water at all: hydrogen peroxide (H2O2) is introduced into the bottle and cap for disinfection, and the hydrogen peroxide (H2O2) is evaporated with hot air, and then the container is evaporated with hot air. The dry valve technology is applicable to all kinds of containers, regardless of the bottle shape and size. Even the hard to reach position like the handle of the plastic decanter can be disinfected. The small and closed part of the container is sterilized by the patented micro isolation technology (micro sterilization room)

dry valve aseptic cold filling technology can save 50% of the cost.

the sterilization medium used for wet sterilization is mostly polyacrylic acid PAA, which is expensive, so it limits the application of aseptic cold filling technology to a certain extent. The sterilization medium used in dry valve technology is H2O2, which is much cheaper than the traditional sterilization medium polyacrylic acid PAA. Moreover, the traditional sterilization production line consumes a lot of water and costs a lot. KHS has compared the two technologies in Europe. Compared with the traditional wet sterilization technology, the dry valve technology can save 50% of the cost

krones' new sterilization method

is similar to KHS. Krones also provides customers with a choice between dry sterilization and wet sterilization systems. Andrew Wilson of Krones said, "we launched our own hydrogen peroxide D dry sterilization method at the Drinktec exhibition, and we believe that this technology will make a difference. We hope that the two technologies (dry sterilization and wet sterilization) can keep pace, although we think peracetic acid (wet sterilization) will still dominate." Krones noted that peracetic acid (wet sterilization) still has obvious advantages in filling lightweight and thermosensitive plastics. Mr. Wilson pointed out that Krones hydrogen peroxide dry sterilization is a real "dry" technology, and the use of pre heating bottle means that there is no condensation treatment, because it is not necessary to use sterile water for sterilization, and only use sterile air

in addition, Krones introduced a new FDA sterilization method for PET bottles, further expanding its product range. This sterilization method meets the standards of the U.S. Food and Drug Administration (FDA), and is specially designed for weak acid products. The introduction of the new sterilization method once again reflects the business philosophy of Krones company: a need, a solution

it is suitable to use hydrogen peroxide D dry sterilization method

under what circumstances is it recommended to use hydrogen peroxide D dry sterilization method in PET bottles? Experience tells us that there are the following three situations: first, the milk processing industry has already popularized the hydrogen peroxide sterilization method; 2、 Customers want to change the flexible packaging to sterile PET bottle packaging due to market demand; 3、 Carton filling enterprises who are familiar with and used to using hydrogen peroxide as disinfectant

the third case is for enterprises that want to reduce the cost of water. According to Krones' method, when using hydrogen peroxide dry sterilization method, there is no need to wash the bottle, so that additional water consumption can be avoided

the hydrogen peroxide sterilization method does not need condensation

this hydrogen peroxide sterilization method is not the former hydrogen peroxide sterilization method. Krones has now embarked on the road of real dry sterilization. When using this method, the hydrogen peroxide shall be dropped onto a heating surface to produce gasification and activation, and then the vaporized hydrogen peroxide shall be carried away by the hot air flow. Blow the air saturated with hydrogen peroxide into the preheated bottle, disinfect the bottle surface, and then blow the air without residual hydrogen peroxide (0,5 ppm H2O2) out of the bottle. Due to the effect of double oxygen water gasification, the log 5 sterilization effect based on Bacillus subtilis can be quickly achieved. Another advantage of Krones dry sterilization method is that the gasification step is completed before entering the container

the use of condensed hydrogen peroxide sterilization method needs to increase the bottle weight to a certain extent

in comparison, the condensed hydrogen peroxide sterilization method can only reduce the bottle weight to a limited extent. When using the condensed hydrogen peroxide sterilization method, the relationship among sterilization effect, bottle shrinkage and hydrogen peroxide residue should be considered, and a compromise method should be adopted. Due to the high heating temperature of hydrogen peroxide, the bottle must have considerable stability, that is, more PET materials are required to make the bottle

to increase the impact of PET materials on the production cost of a filled bottle, take the following full line figure of 3600 bottles as an example:

take the power consumption and production medium consumption (steam, water and working air) of a Nordic factory as an example, the power consumption cost of Krones PET bottle L sterilization method per 1000 bottles is 0.9 euros, The power consumption cost of Krones PET bottle D sterilization method and hydrogen peroxide condensation system sterilization method is 1.3 euros; In terms of medium consumption: the medium consumption cost of wet sterilization method is 1.3 euros, and that of dry sterilization method and condensation system sterilization method is 1.0 euros

however, among all factors, the material consumption has the greatest impact on the production cost: Based on the lighter 1.5-liter disposable pet bottle (with a diameter of 28 mm and a bottle weight of 34 g), and the sterilization must meet the minimum shrinkage of the container (less than 1% of the rated volume) and the minimum residue of hydrogen peroxide (0.5 ppm). For every 1000 filled, labeled and packaged bottles, The material consumption of Krones' dry and wet system sterilization method is 119.45 euros

if the sterilization method of hydrogen peroxide condensation system is used for sterilization, and to achieve the same sterilization effect and residual and shrinkage, the bottle weight shall be at least 37 G. For every 1000 bottles, the cost is 124.33 euros. This calculation result shows that the material consumption difference between Krones non condensing hydrogen peroxide dry sterilization method (PET bottle D sterilization method) and peracetic acid wet sterilization method (PET bottle l sterilization method) is not very large. However, in terms of power consumption and water consumption, each has its own advantages. As the hydrogen peroxide evaporation time required by the condensed hydrogen peroxide sterilization method is long and the corresponding machines are large, especially the consumption of PET bottle materials must be increased, resulting in an increase in costs. For 1.5 billion times of filling, if the weight of each bottle is increased by 3 grams, the annual cost consumption will increase by about 73200 euros. This example clearly shows the great impact of packaging materials on production costs. In contrast, the impact of energy consumption and medium consumption on production costs is only second

power consumption cost medium consumption material consumption

l sterilization method 0.9 Euro 1.3 euro 119.45 euro

d sterilization method 1.3 Euro 1.0 euro 19.45 euro

hydrogen peroxide condensation system sterilization method 1.3 Euro 1.0 euro 124.33 euro

information source: packaging machinery

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