Vitamin Water and Juice Project
Vitamin Water, Orange Juice, Mango Juice, Pineapple, and others as per client choice
|Product: energy drinks|
|Filling speed: 4,000BPH (600ml)|
|Filling temperature: 88-92℃|
|Bottle material: PET|
|Cap material: HDPE or PP|
|Environment temperature: unconfirmed|
|Power supply: unconfirmed|
Description of Production Process
According to configuration proposal, through air conveyor, bottles are feed to water rinsing, filling, capping 3-in1 mono block. Bottles are rinsed by sanitizer and sterile water, filled with the product material and then conveyed to downstream packing system by conveyor after capping. In downstream packing, first, the bottles are dried by the air-blow drier, then production date and mark are printed on the bottles, then sleeve labeling and shrinking. After light inspection, the eligible bottles are packed into cartons or shrink film, then palletized and up to inventory.
Production process as follows:
Sterile material preparation: material with feeding temperature ≤30℃ is treated by automatic plate-type UHT in the temperature of 121～137℃
for 5～20s, then sterile material comes out. The sterile material is feed to filling system after chilled to 85～92℃.
|2.||PET bottle rinsing: PET bottle which reached operation technique requirements are conveyed to bottle rinsing, which performed by water rinsing both inside and outside of PET bottle, after that, the bottle is feed to filling system.|
|3.||Product filling, capping: sterile material is filled to cleaned bottle by CIP cleaned filling system, after sealing by the capper, the semi-product comes out.|
|4.||Semi-product headspace sterilization: capped semi-product conveyed to headspace sterilization chain, which bend over the filled bottle, sterilizing the cap twice by product own temperature; soften the washer of the cap to improve airproof degree between the bottle and the cap. Time for headspace sterilization is over 30s. After sterilization, bottles are held upright again by the chain, then enter the next procedure.|
Cooling of semi-product: after headspace sterilization, the semi-product is feed to showering tunnel, which uses two cycles of recycling
chlorine added water chilling the temperature of product to 40℃ below. Usually, we use pure water rinsing the bottle body before exiting the tunnel.
|6.||Product after-packing: after chilling, the semi-product dried by drying, sleeve labeling, shrinking and wrap-round case packing equipment which owned by customer to turn out to product.|
Fully-automatic Plate UHT Sterilizer
Automatic plate UHT is developed according to the technological requirement of hot temperature filling line, through the direct connection between UHT and filling machine, synchronized control will reduce the degree of second pollution.
|hot water supplying system 1 set|
|tubular heat exchanger|
|product pump 1 set|
|product balance tank 1 set|
|electrical control cabinet and automatic control part 1 set|
|steam pressure reducer and adjusting system 1 set|
|temperature adjusting system 1set|
1) Sterilization parameter and control precision
See the following parameter
2) Heating medium
a) Heat source of the system using the 0.6MPa once saturation steam.
b) Heating medium of Sterilized material is hot water.
c) Exiting cooling medium is chilling water.
d) Chilling medium of recycling product is chilling water.
Main structure parameter
a) thickness stainless steel pre-and-post plywood: 27mm-30mm
b) thickness of stainless steel middle clapboard: 70 mm
c) thickness of heat-exchanger chip: 0.5-0.6mm
|Suitable Material||Energy drinks|
|Material Inlet Temperature||25℃|
|Sterilizing Temperature Control Accuracy||±1℃|
Air conveyor is horsed on the floor, with fan installed on the top. Air filter is positioned at every entrance of air fan, to prevent dust blown into bottles. Bottles are blocked on the neck in the conveyor and transported into filling machine by blowing power. All are made of stainless steel SUS304, except the horses, board of plastic and nylon.
1) Model of fan: F-9
2) Q’ty of fans: one in every 6 meters
3) Power of fan: 2.2KW／Unit
4) Length of air conveyor: according to plant layout
RXGF series 3-in-1 hot filling monoblock is composed of rinser, filler and capper, which adopts and absorbs advanced technology and is manufactured according to juice/tea beverage production technical requirement. It uses outer-circulation pressure filling method with sound CIP cleaning function.
Air conveyor is directly linked with feed-in starwheels, making it easier to change bottles without screws and conveyor chains. Equipped with pneumatic block bottle device.
The rotary wheel is a fully SUS304 stainless steel welded structure.
The machine applies unique overturning bottle clamp, which is an innovation of our company. This bottle clamp grips bottle at neck position, avoiding bottle mouth thread contamination caused by rubber gripper block of a traditional bottle clamp. Made of SUS304 stainless steel, this bottle clamp is hygienic and durable.
The high efficiency atomizing spay nozzle installed on bottle clamp is capable of cleaning any part of bottle inner wall, and also saves rinsing water.
All sliding bushes of lifting device use Igus (Germany) anti-corrosion maintenance free bearing. The rinser is driven by driving system positioned inside machine frame via gear transmission.
Made of stainless steel of superior quality.
Rotary wheel fully made of stainless steel SUS 304. Gravity filling method. Filling valves are made of SUS316L.
Filling valves are reasonably structured with accurate filling. Bottles go up and down in the function of cam through elevator, to process filling with contact to bottle-mouth.
SUS316L pipeline separator without filling bowl, easy for CIP cleaning
Filler is driven through gears inside the machine frame. Link-wheels in rinser, filler and capper are transported in ringed support of bottle-neck.
Capper is the machine with highest precision, influence very much with the stability and reliability of the filling monoblock. Our capper features as follows,
|The equipment is designed with the support of experts from school of engineering and mechanical in Shanghai Jiao Tong University, and developed with the experience of asepsis filling machine. For example, I) extruding wheel (main part to control the stability when sealing). Kinematical and kinetic design of the wheel by experts improves the stability and credibility of the equipment. II) Sealing faucet (main part to control the credibility of sealing), is improved by experts with the design of alnico. Besides the magnetic contortion variation device, there is variation dial which makes variation more easily. The benefit of this design is not only it can set the contortion, but also it makes contortion more precise and credible, and reduces inferior.|
|Cap distributing chute is equipped with reverse cap stop and reverse cap pick-out mechanism.|
|Cap distributing chute is equipped with a photocell switch to stop the capper when there is no cap inside the chute.|
|The capper is equipped with inlet bottle detection switch.|
|Centrifugal way of cap arranging is adopted to reduce damage of caps.|
|I. Discharge starwheel|
|Nylon starwheel and conveyor belt work together to discharge bottles.|
|II. Discharge conveyor|
|1) Driving motor is frequency inverted to synchronize with the filling line to prevent bottles from falling|
|III. Machine frame|
|The machine frame is a welded structure of high quality carbon steel with the surface anti-rust treated and coated. The machine frame is wrapped with stainless steel sheet (SUS304).|
|Driving system of the 3-in-1 Unit is positioned under the machine table. One main motor provides driving power via gear transmission.
|The gear transmission system is an interleaved arrangement of steel gears and nylon gears.|
|The output shaft of the main motor is equipped overload protection to secure machine safety.|
IV. Electrical control system
|Bottle infeed and outfeed system|
7. Main configuration
Material of filling valve: Stainless steel SUS316L
|Material of rotary tray and machine platform of rinser and filler: Stainless steel SUS304|
|Main motor: ABB, Nord or SEW.|
|Sliding bearing: Igus.|
|Frequency inverter: Mitsubishi.|
|Touch screen: PROFACE.|
|Pneumatic components: FESTO.|
|Photocell switch: Banner|
|Proximity switch: TURCK|
|Ø Number of working positions: rinser 14, filler 12, capper 5|
|Ø Rated capacity: 5000BPH (500ml) subject to viscosity.|
|Ø Air supply pressure: 0.7MPa|
|Ø Air consumption: 0.8M3/min|
|Ø Rinsing water pressure: 0.2-0.25 MPa|
|Ø Consumption of rinsing water: 1 ton/hr.|
|Ø Way of filling: Pressure filling|
|Ø Main motor power: 1.5 KW|
|Ø Installed power: 2.42 KW|
Cap sorter is equipped with testing switch, when caps are consumed to a certain degree, testing switch will signal to start feeding to cap elevator. There are certain amount of caps in the cap store, which will be fallen into air pipe in the function of vibrating motor. Caps will be conveyed to cap sorter through air conveyor.
Vibrating motor: 60W
Dimension: 1200×700×1260mm (L×W×H)
The equipment is developed to match the hot filling beverage producing line, It have product inclined , using the product own temperature to sterilize the cap for second time, and soft the air -proof washer of caps, to tighten the closely between the bottle and cap. Sterilization time is 5-10s. After sterilization, the conveyor will make the bottle stand automatically. In the whole process we use two vertical bars for direction, and have bottle inclined, continue the sterilization time and stand automatically. The whole process is stable.
|Main engine adopts variable speed, it is easily to set the producing speed.|
|The whole body is stainless steel (SUS304), clean and sanitary outlook.|
Material in the bottle embellish the bottle mouth completely and special device can be set to fulfill the track vibration in the process of bottle forwarding, and material in the bottle interchange the heat.
|Conveyor system is using the macromolecule material, join the heat-endurable board and stainless steel fringe, the platform is flat and little abrasion|
|Wide fringe board is equipped with the heat-endurable rubber washer to ensure the gap in the whole process, ensure the stable forwarding of the bottle.|
1. Rated capacity: 5,000BPH (500ml)
2. Conveying belt speed: 0~30m/min
3. Effective bottle side-down length: 6m
We absorb the abroad equipment technology, newly-designed this machine, using circular chilling water cooling four-section for treating. During cooling, according to customer's requirement to adjust speed by inverter, which is suitable for cooling of all kinds of non-carbonated material, such as tea beverage, fruit wine, sauce, vinegar, juice, etc.
|the whole body is made from stainless steel (horse, bearing, engine excluded), observing window can be set to around the base, the top structure can be opened for easy maintaining.|
|sprayer adopts the technology of American Spraying Systems Co.|
the recycling filtering device and alarming system is equipped to the water gathering slot in the cooling tunnel.
Cooling capacity: 4,000BPH (600ml)
Effective cooling area: 6.2×1.2m2
Conveying belt speed: 0～1.2m/min
Cooling time is adjustable and main motor is controlled by inverter
The fast flowing air from the blow of the high-pressure fan is sprayed out of an aperture, to remove the remaining waters from bottles to a high extent. The aperture is side-positioned to blow all sides of bottles with fast flowing air.
|Pressure equalizer box|
Ventilator power: 5.5 kw for each
Air pressure: 40kPa
l Air speed: 100m/s
l Air flow volume: 2520M3/h
Bottle conveyor is in great influence with the efficiency of line operation. In the downstream of the line, a short break of the machine (eg. Label change) should be considered, but in the forepart, there should be no influence. The two parts should be connected perfectly to ensure the efficient operation of the whole line. Our arrangement of the line is fully concerned with the relationship between investment and efficiency for the Buyer, which is in fine compliance with the above requirement. With application of advanced technology from abroad, the structure is newly designed, and most of the components are formed up through pressing and bending, which are fine in capacity, low in weight and good in exchanging. The driving system operates reliably and easy to maintain. PLC is invited in the operation of electrical control system, with automatic speed deceleration and buffer.
|The conveyor works smoothly and reliably through the parallel control of belt and main machine or the link-control of the equipments of forepart and downstream without fallen bottles, clipped bottles and blocked bottles in operation. The buffer table (about 2 minutes) can be positioned before labeler according to the requirement of the Buyer. When labels need to be changed, the filler in forepart don’t have to stop with its product stored in the buffer table. When labels are changed, labeler will work on with the stored bottles in a high speed to resume the parallel speed.|
|The conveyor is designed on module, with strong exchanging ability, compact structure, low noise and convenient installation and operation. It is flexible in different capability and bottles.|
The electric control is designed reasonably. It can be designed according to the layout of the Buyer, and to choose necessary components, improving the stability of the transportation.
|The switch is positioned reasonably according to the conveyor arrangement and requirements from the Buyer, to make it convenience for the operation of the Buyer.|
|Main components are made of stainless steel with chain from macromolecule plastic, electric components from SIEMENS.|
|Central lubricating system is used to lubricate bottle conveyor, which consists of spray nozzles, pump station and pipeline. Lubricating to the main points of conveyor can be realized during working.|
9000 series is a printer of the highest integration degree and smallest volume, which is a leader of top technology with easy and stable operation. Various models of different characters are customized for your needs, eg. different lines and display rate.
Two lines of changeable information can be printed.
|Touch screen operation|
|Touch screen button for on and off.
Fixed operation screen, with figure-key for different purposes, which is easy to handle.
S7 Sigma is smaller than any printers in the market.
Height: 512mm Length: 215mm Width: 236mm
Replaceable interface-box contains all connection parts for installation, making it easy for printers to move among lines.
Module-design and automatic controlled program allow easy operation and maintenance of S7Sigma;
Two types of ink-box are applicable to the demand of different production.
Application of high technology enhances sustainability.
MB-10 machine has been designed for no tray, no cardboard case, packing with low cost in the operations, it is widely used in food, beverage, chemical and office industries
Machine dimension: 5150mm×2470mm×1940mm (L×W×H)
This system is applied in the conveying of products after packing with newly designed structure. The frame is pressed or bended to shape with fine rigidity and low weight. The roller-canister is made of S/S, the motor and reducer are products from Joint Venture, very reliable operating and easy to maintain.
Way of working: No-pressure roller conveyor.
Today, drinking water is more and more important for human life. Clean, Pure, Sanitation, Health is most important for drinking water.
As a earliest developer, manufacturer of water treatment equipment,
We always do our best for people in Drinking water. There are 3 tenets of our company: “Enterprising” “Innovation” “Perfection”
GIECL Take the Complete Turnkey Projects as per Customer's Requirements. GIECL has Affiliation with related Machineries manufacturers and have executed such Projects Nationally and Internationally
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