More flexibility for preform sterilization

Is it possible to combine exceptional flexibility with maximized line performance in aseptic filling? The Krones development team has worked intensively on this very question. And one look is enough to see that their solution is unlike anything that has come before.

The Contipure D module has been a classic fixture in Krones’ portfolio for years. It sterilizes preforms with gaseous hydrogen peroxide (H₂O₂), creating the ideal conditions for the microbiologically safe filling of sensitive beverages. “What customers who use Contipure appreciate most is the system’s low resource consumption. And of course, the fact that they can depend on repeatable sterilization performance,” says Peter Igl of the Plastics Technology product management team.

Because the system has proven itself time and again in actual practice, we thought it was time to tackle a new challenge: “The topic of ‘flexible production’ is currently on the minds of many of our customers,” explains Peter Igl. “Which is why we have upgraded the Contipure in such a way that a single module can accommodate varying container sizes and output rates.”

Scalable multi-level design

To that end, the team developed a completely new preform starwheel. Vertically, it consists of up to three process levels stacked one above the other; horizontally, it is divided into several individual segments that can be separated and repositioned independently of one another. This novel multi-level design is visually striking and – more importantly – allows for flexible scaling of production. “The individual levels can be turned on or off as needed,” says Peter Igl. “For line operators, that means they can flexibly adjust both capacity and sterilization time. It also means that a single modularized solution now covers the entire performance range, which in turn makes planning and designing complete systems a lot simpler.”

The new preform starwheel in a multi-level design

Up to 40 percent more sterilization time

The vertical arrangement of the process levels – replacing the previous, horizontal, three-starwheel layout – makes the module significantly more compact. Depending on the application at hand, it can also enable the line to run up to 38 percent faster compared to the previous generation. At the same time, the system offers the option to extend the H₂O₂ exposure time in certain output ranges by up to 40 percent if needed for the respective process. For most applications, however, this is not necessary.

Development work also focused on minimizing wear and tear. Innovative design solutions such as optimized preform handling, precise lifting mechanics and a robust isolator design ensure stable process conditions combined with reduced maintenance requirements. Moreover, the hygienic design – with a clear separation of the process area from the drive area – prevents contamination. Optimized processes and optional, integrated recirculation technology also reduce the system’s media consumption.

“We felt it was important not to simply make isolated improvements to the module. Instead, we wanted to start an entirely new chapter in preform sterilization,” stresses Peter Igl, adding that “the first of the new machines are already up and running at customer plants. Which means that our new development has reached series production and is ready for global deployment.”

#PET #rPET #Filling #SustainableProduction #Aseptic

Angelika Krempl

02. September 2026

2:35 min.

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