High-speed filling of non-carbonated water in PET containers
In machine production, there are physical limits in machine production when trying to increase performance. In order to also ensure stable production in high-speed environments, Krones divides the bottle flow into two modular filling and capper units. For the very first time, this allows an output range of 100,000 containers per hour to be achieved while filling PET bottles.
At a glance
- Division of the bottle flow onto two filler and capper carrousels
- Infinitely adjustable control of the flow speed thanks to PFR* technology
- Services: Up to 100,000 containers per hour (in ErgoBloc L or Contiform Bloc BF)
Method of operation
At peak times over 100,000 - optionally pre-labelled - bottles are divided up onto two filler carrousels with the help of a distributor module in the filler. Proven and robust filling and capper technologies enable you to get exceptional results. After final inspection, both bottle flows are combined again and processed further.
The components
- Two Modulfill VFJ fillers with inductive or mass flow meter
- Two Modulcap CM cappers (optionally with single-head drive)
- Capcade sorter for the cap feed unit and subsequent division
- Adjacent product tank
- Optional: UnitXpress module for the Modulfill to change-over product completely automatically
Modulfill VFJ free-jet filler
Functional principle of the valve
Neck-handling grippers position the PET container beneath the filling valve. Once the container has been centred, the filling process starts: During this process, the PFR valve (Proportional Flow Regulator) is opened and the product flows into the bottle with infinitely variable speed. Once the required fill volume has been reached, the flow meter provides a signal to the PFR valve. The valve is now closed and the filling process completed. Dripping of the filling valve is prevented by a sieve in the product discharge.
Optional
Additional channel for CIP cleaning
- Conductivity > 20 µS/cm
- Viscosity < 10 mPa·s
The cap feed unit
The Capcade sorter takes on the task of sorting up to 100,000 caps per hour. Different technical optimisations make this increase in output possible. The caps are sorted, inspected, buffered and divided onto two capper carrousels.
Technical details
- Efficient cascade sorter for cap sorting in high-speed environments
- Division of cap flow onto two capper carrousels after the accumulation table
- Perfect inspection of the cap quality and optimum system buffer characteristics
- Low-level or raised machine installation
This is why the Modulfill Dual is enviro-classified
Lower media use thanks to PFR technology: 30 percent lower compressed air use than with conventional filling valves.
Benefits to you
Infinitely adjustable control thanks to PFR technology
The PFR valve (Proportional Flow Regulator) is a solution to control the product flow by means of an electronic controller and an integrated stepper motor. By regulating the product flow in front of the filling valve, products can be optimally adjusted to fit the bottle geometry.
High-speed and stable performance
In order to fill 100,000 containers per hour, Krones did not simply increase the size of the machine, but instead divided the bottle flow onto two small filler and capper carrousels. This way, smaller physical forces influence production and the overall system performance is increased.