More flexibility for preform sterilization

• New Contipure D module with up to three vertically stacked process levels
• Depending on the application, speed increases of up to 38 percent compared with the previous generation
• Capacity and sterilization time can be flexibly adapted to different production requirements

With a new generation of the Contipure D module, Krones is bringing greater flexibility to the aseptic filling of sensitive beverages. The centrepiece of this further development is a newly designed preform starwheel featuring a multi-level design. It enables different container formats and output rates to be handled with one and the same module, allowing line performance to be flexibly adapted to specific production requirements.

The Contipure D module has been part of the Krones portfolio for many years. It sterilizes preforms with gaseous hydrogen peroxide (H₂O₂₎, creating the conditions for the microbiologically safe filling of sensitive beverages. In developing the new generation, particular focus was placed on the increasing demand for flexibility in production.

“The topic of flexible production is currently on the minds of many of our customers,” says Peter Igl from Product Management Plastics Technology at Krones. “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 achieve this, the preform starwheel was completely redesigned. Instead of the previous horizontal three-starwheel layout, it now consists of up to three process levels stacked vertically on top of one another. Horizontally, it is divided into several individual segments that can be separated from one another. The individual levels can be turned on or off as needed. This allows both capacity and sterilization time to be adjusted flexibly to meet different production requirements.

At the same time, a single module concept now covers the entire performance range, simplifying the planning and design of complete systems.

The vertical arrangement also makes the module significantly more compact. Depending on the application, the new design can increase speed by up to 38 percent compared with the previous generation. In defined performance ranges, the H₂O₂ exposure time can also be extended by up to 40 percent where required by the process.

Reduced wear and media consumption

Another focus during development was the reduction of wear and tear. Optimized preform handling, precise lifting mechanics and a robust isolator design ensure stable process conditions while reducing maintenance requirements. The clear separation of the process area from the drive area further enhances hygienic safety. Optimized processes and optional integrated recirculation technology additionally 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,” emphasizes Peter Igl. “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.”

About Krones

The technology company Krones, headquartered in Neutraubling, Germany, is a leading international developer and manufacturer of state-of-the-art machines and complete lines for the areas of process, filling, and packaging technology. Additional products and services from Krones subsidiaries, such as solutions for digitalization, intralogistics, as well as injection moulding and plastics recycling, complement the product portfolio. Krones employs more than 21,000 people worldwide. Sales in 2025 amounted to EUR 5.66 billion. In addition to the listed Krones AG, the Krones Group includes more than 100 subsidiaries and locations worldwide.