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    Contipure Bloc P
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    Ultrahygienic block for sensitive products Contipure Bloc P

      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

      00 - Article Item 24479
      Brochure Krones Contipure Bloc P
      1.65 MB, .pdf

      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

      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
       

      Cap sorting and inspection
      Media module

      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
       

      Central ventilation technology

      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.
       

      Valve manifold

      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

      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.

      The facts:
      everything you need to know about rPET

      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.

      Preforms
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      Preforms

      In the preform production process, every tenth of a second in cycle time and every tenth of a gram in weight count. And there are plenty of potentials for meaningful savings. To exploit them, two things are necessary: firstly comprehensive knowledge of the properties and the behaviour exhibited by the various preform materials, and secondly a profound insight into the production processes involved – both into preform injection-moulding and into the salient aspects governing subsequent container stretch blow-moulding. You will find both of these in the Krones Group.

      MHT AG, a company that has specialised in making PET tools for producing preforms, has been part of the Krones family since 2018. Its performatively excellent high-tech injection-moulding tools

      • image all preform designs and threads in common use;
      • are suitable for almost all machine platforms known on the market;
      • are based on an innovative hot-runner technology developed in-house.

      MHT Mold & Hotrunner Technology AG

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      Individual solutions and complete factories

      Would you like to produce preforms and caps made of recycled or new material? A company of the Krones Group will assist you here as well: the Integrated Plastics Systems AG – briefly IPS. Among others, the following services are offered:

      • From engineering of systems for preform and cap production all the way to turnkey factories
      • Sustainable saving of material and energy consumption
      • Customised container design

      Integrated Plastics Systems AG

      Containers
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      Containers

      The ideal package offers persuasively attractive pluses in all situations: in the production process and at the point of sale, during transport and finally during recovery as well. Since Krones has signed up to providing holistically conceived solutions, development work on both bottle design and machine technology goes hand in hand. It is only when both these aspects supplement each other to perfection that the best solutions are arrived at – for producers, consumers and the natural environment alike.

      The packaging designers from Krones

      • advise clients on design, material, product requirements and technical implementation of packages;
      • optimise existing designs in terms of weight, haptics and line efficiency;
      • possess in-depth expertise in the ecological and economic requirements involved, such as material selection, recyclability or weight optimisation.

      A whole bandwidth of different technical solutions can be found in the Krones portfolio for the journey from the preform to the ready-for-sale product. And the innovation process embraced by Krones sees to it that these solutions grow in line with more stringent market requirements and also provide answers to the challenges of tomorrow. One element of crucial importance in this context is the enviro sustainability programme, because it makes sure that any newly developed products, and any upgrades, too, are focused on eco-efficiency and environmental compatibility right from the start.

      Product information Bottle Design

      Sustainability Programme enviro

      Contiform 3 Pro: a stretch blow-moulder series that

      • has been conceived for outstanding energy- and media-efficiency;
      • covers a wide output spectrum;
      • reliably masters a most varied range of process types – on request in one and the same machine;
      • also produces PET bottles made 100 per cent of recyclate.

      Product information Contiform 3 Pro

      Contiform 3 Speed: a high-speed stretch blow-moulder that

      • achieves a station output of up to 2,750 containers an hour;
      • produces containers for still water, CSDs, and sensitive products;
      • saves another max. 15 per cent in energy and compressed-air consumption compared to the Contiform 3 Pro.

      Product information Contiform 3 Speed

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      Contipure AseptBloc: aseptic filling systems that

      • also produce and fill lightweight containers to optimum standards of quality;
      • boast an uninterrupted running time of up to 186 hours;
      • are extremely painstaking in economising on energy consumption;
      • need just one single sterilisation medium – and use this with particular efficiency.

      Innovation Contipure AseptBloc E

      Product information Contipure AseptBloc DN

      Product information Contipure AseptBloc DA

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      Tethered caps: Be prepared now for the EU Directive 2019/204

      It will be mandatory in the EU from 2024 for non-returnable PET bottles: Tethered caps - i.e. caps that remain firmly attached to the bottle even after opening. We want to make it as easy as possible for you to switch to the new cap type. That's why we have prepared our capping technology for the new task - and also summarised all the important information about tethered caps for you in a whitepaper: From the legal situation regarding possible cap variants through to their technical feasibility in the production line.

      Downloading the whitepaper free of charge

      Secondary packaging
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      Secondary packaging

      When it comes to reducing the use of materials, we mostly think of the beverages containers first. But if we take a closer look, we can see that there is also plenty of savings potential with secondary packagings.

      Doing completely without plastics

      It is also possible without film: LitePac Top is an innovative secondary packaging from our own development. Instead of shrink film, it keeps cans and PET containers in shape with an environmentally friendly cardboard clip - and thus meets the pulse of the times in terms of sustainability and resource conservation.

      Packaging your containers without film

      The difference to many other alternative packaging types: LitePac Top can already be produced on an industrial scale today - and is thus ready for immediate use on the market. This is because the Krones Varioline can handle the most diverse types of secondary and tertiary packaging, including LitePac Top. 

      Discover the many possibilities offered by the Krones Varioline

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      Consuming less plastic 

      You don't always need a new type of packaging: There's also still plenty of material to be saved in existing pack types. 

      Optimising the machines 

      The Variopac Pro packaging machine offers several options for noticeably reducing shrink-film consumption - by upgrading to reduce:

      • the film thickness by up to 25 μm.
      • the lateral film projection.
      • the film residue on the film reel.
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      Optimising the packaging material

      A service for all those who use shrink films optimally:  In a film analysis, we examine and evaluate the films you have selected based on all of the relevant parameters. The results will be sent to you in a conclusive report with clear evaluation graphics – which provides you with an ideal and, above all, objective basis for making decisions during film selection. Whether material thickness, overlap or overhangs: even when it comes to recycling films, we will gladly accompany you to the limits of what is technically feasible. Benefits to you: More sustainability with lower costs! 

      Try it out right away: use the free savings calculator and send a non-binding enquiry

      Used PET bottles
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      Used PET bottles

      In a recently announced co-operation agreement, Krones and Stadler Anlagenbau GmbH are lighting the touchpaper for a strong circular economy. The shared aim is to make the benefits of plastic recycling a reality that is as achievable and profitable as possible for customers all over the world. Firstly, by offering their existing, tried-and-tested solutions for sorting and recycling technology as turnkey complete factories from a single source. And secondly by collaborating on the development of new solutions, processes and technologies to do with the sorting and treatment of waste.

      Stadler Anlagenbau GmbH

      • is one of the market leaders in the sorting systems technology
      • has about 450 employees
      • has sold already more than 350 turnkey lines and 2,000 single components worldwide
      • develops and manufactures technology for sorting all kind of different materials – this includes plastic waste, paper, cartons, household waste and commercial waste.

      Stadler Anlagenbau GmbH

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      Recyclate
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      Recyclate

      Buy, drink – and that’s it? Not by a long way! From a consumer’s viewpoint, the lifespan of a PET bottle may seem short. But the bottles themselves know better. After all, they are made of a material with outstanding recycling properties. And that talent can be utilised again and again.

      So it is all the more surprising that billions of PET bottles per year are still not being re-used – meaning a gigantic raw-material source is simply lying fallow. The Ellen MacArthur Foundation estimates the value of plastic waste unused today at 80 to 120 billion dollars a year. An enormous potential just waiting to be tapped. And that’s not all: recycling plants turn waste into new products – and can thus make a substantial contribution towards reducing the global littering problem.

      The MetaPure recycling systems

      • … recycle PET containers
        • into flakes (on request with direct downstream processing into new products).
        • in different material qualities.
        • right up to food-grade PET in line with FDA, EFSA and other certificates.
      • … recycle containers made of polyolefins (PO)
        • into flakes.
        • in the upcycling approach for high-quality re-use.
      • … are available as individual machines – or in the shape of a complete single-sourced recycling plant.

      Product information MetaPure

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