As you know, the trend of healthy eating is accompanied by the trend of safe production and packaging technologies, both of which are aimed at preserving the product's health benefits and organoleptic properties. Let's talk about the benefits of aseptic technologies for filling juice drinks into PET containers, which have grown in popularity over the past few years and are still growing rapidly.
Environmentally friendly and safe
The modern trend of healthy lifestyles and balanced nutrition undoubtedly influences the consumer's decision when choosing a product.Today, consumers are looking for environmentally friendly and healthy products. Therefore, the composition of food and beverages, namely the presence of healthy ingredients along with the absence of preservatives, are crucial factors. hot bottling.
Speaking about reducing the total cost of production per unit of output, we need to understand what exactly this indicator depends on.
Uniqueness depending on the composition
First of all, it means the ability to use lighter containers due to the absence of a shrinkage margin - as in hot bottling. Secondly, the use of this technology greatly simplifies the distribution of finished products, meaning that there is no need for a "cold section" of the supply chain, as the products can be transported at normal ambient temperatures. Longer shelf life also gives the manufacturer more time to sell the goods. Aseptic technology, which initially carried a certain uniqueness, continues to evolve and improve. In addition to the fact that aseptic filling differs in its technology depending on the type of beverage, the composition of the product itself is an important aspect. Therefore, when talking about juice and juice-containing beverages, it is worth taking into account such factors as the percentage of juice, CO2 concentration, presence of pulp, fibres and their concentration, presence of pieces and their size, and the shelf life and storage conditions of the finished product. All these factors will undoubtedly influence the type and design of the filling unit.
GEA Procomac - the queen of asepsis
The very concept of cold aseptic filling of juices and beverages has long been associated with its "author" - GEA Procomac (Italy). This company is one of the few that has chosen its path "from complex to simple". Having started its development with aseptic technology and gained a leading position in the global market for sensitive beverage filling, the company has gone on to simplify technical solutions to adapt the equipment to other types of filling, the requirements for which are less critical. For example, for the filling of juice and other sensitive beverages, GEA Procomac offers very flexible solutions both in terms of the type of filling machines and their performance. Today, GEA Procomac can offer cold aseptic filling lines with a capacity of 2-3 thousand bottles per hour at an affordable price. This is important for companies that are just starting their way to success, or for those manufacturers who are aiming to launch a new product but are not ready for large investments. In addition to aseptic technology, GEA Procomac specialises in Ultra-Clean filling technology, which is used primarily for the filling of carbonated juice drinks without preservatives and gas-free mineral water.
Dry disinfection technology
Aseptic filling machines include ABF (AsepticBlowFilling), a unique technology for "dry disinfection" of preforms, with blowing, filling and capping in one unit. The peculiarity of this machine is that after passing through the heating furnace, all preforms are treated with a hydrogen peroxide solution and subsequently blown out in a sterile area. This machine can operate at speeds of up to 48,000 bottles per hour with different levels of sterilisation. This means that the same machine can be used to bottle both aseptic beverages (low- and high-acid) and ESL products, water, etc. The machine consumes a reduced amount of reagents compared to traditional aseptic filling technologies, and only one operator is required to operate it.
Handling compact machines
GEA Procomac also offers machines that wet-coat containers with acetic acid. This technology includes the ECOSpin and Modulbloc machines, the latter of which is a low- to medium-capacity machine with compact, overall dimensions.
Innovation - electromagnetic flow meter
It is worth noting that all GEA Procomac aseptic filling machines are equipped with the Fillstar aseptic filler with electromagnetic flow meter, which is the best solution for filling sensitive beverages. A range of FX and CX series valves specially designed for aseptic filling allow for the packaging of still and carbonated beverages:
- without inclusions;
- containing pulp and fibres (3 mm in diameter and 20 mm in length);
- containing pulp and fibres, as well as pieces of 5x5x5 mm. up to 10x10x10 mm.
It is worth noting that the filling of quiet products is carried out in a non-contact way, and each carousel is equipped with self-adjusting grippers, which significantly reduces the time when changing from one neck format to another.
The best solutions are on one line
All of these features make GEA Procomac the undisputed leader in sensitive beverage equipment and the aseptic filling technology the best solution for filling juice drinks.
Today, GEA Procomac is virtually the only company to supply aseptic PET filling technologies on a single line:
- still (non-carbonated) juices and beverages under aseptic conditions in PET bottles with a 28 mm or 38 mm neck diameter;
- carbonated (up to 9 g/l CO2) beverages under aseptic conditions in PET bottles with a 28 mm neck diameter;
- low-acid products (pH between 4.5 and 7.0, which is typical for milk or milk-containing drinks), in which case filling high-acid juices and juice drinks is not difficult at all.
The capacity of this line is from 2,000 to 54,000 bottles per hour.
Shall we meet and discuss everything?
Steiner-Ukraine, the exclusive partner and representative of GEA Procomac in Ukraine, invites you to the international exhibition Inprodmash & Upakovka, where you can discuss current and future projects in a constructive and creative atmosphere (13-15 September 2016 at the IEC, 15 Brovarsky Avenue, Kyiv).