Ultrahygienic block for sensitive products
A protected atmosphere for your product
The Krones family includes experts for all kinds of different sterilisation methods and products to be filled. One of them is the Contipure Bloc P: It is specialised on sensitive products and fully meets their requirements.
At a glance
- Design:
- Preform sterilisation module
- Blow moulder
- Aseptic filler and capper
- Suitable for:
- Sensitive products
- Round, square and rectangular PET containers
- Standard and lightweight containers
- Output: Up to 72,000* containers per hour
* depending on the container type and product
Buying time during cleaning
The performance variant uses hot caustic for machine surface disinfection and reliably sterilises the product channels with steam. This process guarantees microbiologically safe filling in the fastest cleaning and sterilisation times.
The benefits
- Timespan from last to first bottle:
- only 90 minutes – including cleaning and sterilisation
- Saving a full hour compared to other systems
- Only 30 minutes intermediate sterilisation after manual interventions in the block
- Handling parts change-over at the blow moulder:
- Without intervention in the sterile area
- Therefore no intermediate sterilisation required
The key components
Prejet Preform rotary rinser
Technical features
• Compact one-starwheel concept at ground level
• Method of operation:
o Immersion of the rinser lances in the preforms
o Blowing out of the particles with pre-filtered andionised sterile air
o Simultaneous to particle blow out: Extraction of themix of air and dirt
Benefits to you
• Low space requirement with good accessibility
• No unnecessary transfer points as the existing infeed starwheel is used as rotary rinser
• Low number of handling parts, quick tool-free change-over
• Very good cleaning performance
• Low air consumption
Contifeed preform feed system
Thanks to hygienic design optimal for the Contipure Bloc P
Variants adjustable depending on the installation position
Optional
• Completely closed preform feed system
• With fan-based air treatment system (FFU) incl. HEPA filter
Benefits to you
• Controlled air exchange
• Significant reduction in the number of particles within the preform feed system
• Separation of the preform feed system from the existing ambient conditions
Infrared oven
Technical features
• Servo-controlled oven of the Contiform standard series with efficient and pre-filtered preform air cooling system
• Option: Tool-free quick-change of the protective plates of the oven heating mandrels
• Optimised in terms of energy:
o Low dead spaces between the heaters
o Longer infrared radiators
o Use of parabolic mirrors
Benefits to you
• No critical control point (CCP) in oven:
o Easier operation
o No risk of corrosion thanks to the sterilising medium
o Processing of preforms from up to 100 percent rPET
o No revalidation required with change of preforms
• Significantly improved hygiene thanks to additional air filters
• Reduced change-over time and energy costs
Preform sterilisation module
Contipure D preform sterilisation module
Method of operation
• The module is between infrared oven and blowing module.
• Via nozzles, a targeted and directed feed of gaseous hydrogen peroxide (H₂O₂).
• This provides overflow and thus results in a simultaneous internal and external preform sterilisation.
Benefits to you
• 360° treatment for the sterilisation of the complete preform surface at once: inside, outside and neck-finish area
• High-performance preform sterilisation up to log 6
• No sterilisation blind spots thanks to three-starwheel concept
• No further contact with the preform inner side wall after sterilisation
Blowing module
Blow moulder
Improved hygiene standard
• The air used for stretch-blow moulding the PET bottles is filtered beforehand using a pre-filter unit with autoclaveable filters.
• A fine dust filter is also installed on the heating module to ensure that dirt particles such as coal dust, pollen or plant spores are filtered from the ambient air.
Increased flexibility
• Through the blow mould change-over concept, optionally available with robot
CapAsept D cap sterilisation module
Cap treatment system
• Caps are blown out with ionised air right in front of the unit.
• Sterilisation by means of gaseous H₂O₂
• No back-up pressure acting on the caps – no deformation
• Clocked feed of the caps on demand: No bottle – no cap
o Resources are saved
o Optimum treatment of the caps – no over-treatment
Flexibility
• Flat caps and sports caps can be processed with the same handling parts.
Hygiene
• Particles fall through the perforated plate and are flushed during the cleaning process.
Aseptic capper
Technical features
• Every capping head has its own separate servo drive.
• A transfer tunnel separates the sterile area from the outside area.
• The proper technique for every cap – overcaps with round bottle possible!
Hygiene
• The Krones aseptic capper is always in a hygienic design and meets even the most difficult hygiene requirements.
• All drives are outside the clean room housing.
• A liquid seal system seals all of the capper carrousel’s rotational movements.
• The movements of the capping head are sealed with bellows.
• Depending on the type of cap, a cone capper or a gripper capper are used.
Cleaning and change-over
• The open design enables excellent cleaning of all capping heads.
• The handling parts adjustment system operates fully automatically up to a defined speed.
Aseptic filler
Filling valve
• The appropriate filling valve for the most wide range of products – still and carbonated
• It is also suitable for beverages with (fruit) pieces of a size of up to 10 x 10 x 10 millimetres
Cleaning and change-over
• The filler has its own CIP module – thus no separate CIP system is required.
• The filling valves are sterilised with steam.
• The clean room housing is sterilised with hot caustic.
• Handling parts change-over is possible up to a defined output in an automatic way.
• After an intervention into the clean room housing, there will be an intermediate sterilisation with hot caustic within 30 minutes.
• Timespan from last to first bottle is possible within 90 minutes depending on the product.
Benefits to you
Triple protection
The all-round treatment with gaseous H2O2 sterilises the entire preform surface at once: Inside, outside and in the neck area.
Gentle preform treatment
The sterilisation of the preforms hardly leaves any residues: This is because the surface enlarges by many times and the residues of the sterilisation medium are diluted accordingly.
High availability
The complete block production can run for up to 120 hours at a time – and only a short 90 minute sterilisation break is required before it is back in action and ready for the next round. Intermediate cleaning after manual interventions also only takes 30 minutes.
Pinpoint production
Filling to the last drop: The system uses the remaining product quantity in order to calculate exactly how many more PET containers and caps are still to be sterilised.
Fully-automatic change-over
Handling parts change-over at the filler and the capper can be performed up to a defined output without any manual interference.
Flexible production
The optional automation package allows change-overs to be performed on the entire block in under 20 minutes – including the emptying and starting up of the machines. This means that you gain an additional two hours of production time with each change-over – and operators have their hands free to perform other tasks.
Beverage containers made from rPET
Material properties, processability, food grade quality: you can find all kinds of interesting facts about the use of recycled PET in our free white paper.
Everything you need for PET: the closed plastics cycle under one roof
Can plastic packages be sustainable? Yes, they can, if the process for producing them is resource-economical and if they are kept in a closed cycle. You can achieve both of this with technology from Krones and the services it provides. Starting with material-saving packaging design, then low-energy container production right through to recovery of used plastics: Krones offers PET bottles and other packages a chance for a sustainable, eco-compatible life-cycle – not only once, mind you, but again and again.