A block that’s revolutionising beer filling

• At drinktec, Krones is presenting the Dynafill Bloc FL for the first time – a space-saving block concept for filling beer into glass bottles.
• This block requires only roughly 155 square metres of floor space, over 60 per cent less than a conventional machine layout.

In the Dynafill Bloc FL, Krones has combined the Dynafill filler with a labeller (such as an Ergomodul with cold-glue labelling stations) in a compact block. The key to its compact design is this: Instead of multiple transfer worms, just a single, newly developed, pitch-adjusting starwheel is integrated between the filler and the labeller. This starwheel can even out different machine pitches (from 87 to as much as 126 millimetres in both directions), thus minimising the amount of floor space required for the block-synchronised unit. The pitch-adjusting starwheel can be used for other machine combinations as well, such as a filler and a rinser.

But this starwheel isn’t the only factor contributing to the Dynafill Bloc FL’s significantly smaller footprint. The filler itself also plays a crucial role, combining as it does the filling and capping processes in a single unit in which bottles are capped immediately after they’re filled. This block configuration yields multiple advantages. For one, there’s no need for a separate capper. Emptying sections are also unnecessary. Eliminating these components from the line layout significantly reduces the amount of space required. Additionally, the integrated filling and capping sequence also has a positive impact on product integrity and quality since the oxygen content can be 100 per cent controlled.

Technology meets sustainability

The Dynafill is also a powerhouse when it comes to energy efficiency. Because it enables warm filling at up to 30 °C and a maximum filling pressure of 5 bars (without compromising quality, of course), additional tunnel heaters for preventing condensation can be reduced or even eliminated. And that saves both energy and space across the entire line. The Dynafill also enables smaller filler layouts for warm filling: For a rated output of 36,000 containers per hour, the Dynafill needs just 66 filling valves – versus 120 that would be required on a conventional filler.

Space savings of more than 60 per cent

The advantages in terms of space savings become especially evident in a side-by-side comparison of the footprints of the block and a conventional machine layout: Assuming that the two lines are dimensioned for a maximum speed of 60,000 glass bottles per hour, the Dynafill Bloc FL fits on roughly 155 square metres, while a conventional layout of a filler, capper and labeller would take up around 405 square metres. That translates to space savings of about 60 per cent – a persuasive argument for any brewery facing a shortage of space in the production hall.

A further pioneering option is currently undergoing field testing

To save even more space in the block, Krones is currently field testing the integration of an infeed starwheel with long-stator linear motor technology. In the future, this highly flexible concept will replace the customary worm-based infeed and the associated accumulation area, making it possible to regulate the flow of containers on the conveyors and in the machine infeed synchronously. Besides eliminating even more conveyors, this concept also reduces backup pressure, which in turn results in less damage to the bottles and lower noise levels.

About Krones

The technology company Krones headquartered in Neutraubling, Germany, is a global leader in developing and manufacturing state-of-the-art machines and complete lines for the fields of process, filling and packaging technology. Its portfolio is perfectly complemented by additional products and services provided by the Krones subsidiaries, such as solutions for anything to do with digital transformation, intralogistics and plastics recycling. Krones employs more than 20,000 people worldwide. Consolidated sales in 2024 totalled 5.3 billion euros. The Krones Group includes not only Krones AG (listed on the stock exchange), but also more than 100 subsidiaries and further production, sales and service companies worldwide.