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Faster, safer filling and packaging processes developed

Home Manufacturing & Processing Food & Beverage Faster, safer filling and packaging processes developed

ECONOMIC success calls for maximum efficiency and availability in all filling and packaging processes. “We provide innovative and resource-saving systems and solutions that fully satisfy all aspects of this demand,” says Tobias Wetzel, CSO of KHS. The most recent example of this is the new rotary InnoPET BloFill ACF-R aseptic block that combines the energy-efficient InnoPET Blomax Series V stretch blow moulder with the rotary Innofill PET ACF-R filler for the very first time.

Linear fillers can process up to 14,000 bottles per hour. In contrast, the rotary aseptic block has a capacity of up to 36,000 1.0L bottles per hour and will be available in the future with a top output of 48,000 500ml bottles an hour. The new plant engineering achieves a sterility of log 6 inside the bottles – which is equivalent to a reduction in germs of 99.9999%. “Our linear aseptic fillers, also blocked, have long proved themselves in practice in the filling of sensitive beverages into PET bottles, where maximum safety is of the essence. The newly developed rotary aseptic filler in the higher capacity range is thus the next logical step. With this, we also want to set standards regarding the machine’s hygienic properties,” Wetzel says.

Effective protection

KHS focuses on bottle sterilisation that – unlike preform sterilisation – can also be combined with the KHS FreshSafe PET coating system and thus offers additional barrier protection for sensitive beverages. In this variant, all potential germs are removed from the containers directly prior to filling. This process gives bottlers more flexibility and greater availability during format changeovers than preform sterilisation, as here changing the stretch blow moulds disturbs the sterile state of the block.

Regarding barrier protection, KHS has developed a new generation of Plasmax coating technology. With this pioneering technique, a wafer-thin layer of chemically pure glass is applied to the insides of PET bottles, with bottle recyclability nevertheless fully retained. This protects sensitive products such as fruit juice, wine, beer, soft drinks, ketchup, sauces and other liquid foods from oxidation and loss of CO2, meaning that they keep for considerably longer.

Consistent expansion

In addition, the turnkey supplier’s range of digital services is now supplemented by KHS ConnectApp which provides two major extra benefits:

  • Data-based transparency regarding the key line performance indicators and helps with decision-making processes.
  • Support with system operation

The first KHS ConnectApp function is the Guide module that with its interactive work instructions and powerful notification management system helps to ensure trouble-free workflows during inspection and maintenance or when training new employees, for instance. Moreover, all work steps can be documented with the app.

“By expanding our digital service portfolio, and especially thanks to the introduction of KHS ConnectApp, we’re laying the foundations for further optimisation and efficient organisation of the entire system operation and management,” explains Wetzel.

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