Technology of Bottled Water

240 Pages·2011·17.05 MB·English

by  Nicholas Dege

210 aterechnology of Bottled WT
1 st evacuation
saG
Gas needle
Liquid stem
Vent tube
Liquid
channelfeed Product
Vacuum/CIP channel
Snifting/CIP channel
Snifting/CIP valve
Evacuated bottle
Vacuum/valveCIP
. 7.13 Fig reP- evacuation step in preparation for filling glass bottles.
These systems eloped vwere for deproducts that e are vxtremely to esensitioxygen con-
bottling the in quality product ed vimprofor demand increasing the with , odayTtamination.
more becoming are flushing pre- or acuation vepre- with illers fproducts, ater wcarbonated of
desirable.
Whielnlf ingc arbona,at fetadwet rec rompletingti hlelf ingp rocesse,tr vhpeor essurei n
csoutvnrhitrarerrooe e tooufbqmdhnlinb ouaeumatt-lndetanncuthoe i tlnes e dnl edt ger
inlgtaeeptrrrrh neeasae l-l, vi lvlfintgfh reo moremeted vnhbm teoio,rtts wwht ihelse een ,
sure in the bottle owuld cause the contents to spontaneously gush from the bottle. This
reduction in pressure is eadvc hievia a special (cid:145)snifting(cid:146) ael,v vwhich opens after illfing
and wasl lothe pressure in the headspace to be werleod wlsyl ountil it is equalised with
atmospheric pressure without foaming of tehrvea gbee.
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212 aterechnology of Bottled WT
Procedural steps
5
6 4
3
2
1
1 1st evacuation
2 Flushing
3 2nd evacuation
4 Pressurising
5 Filling phase
6 Snifting
. 7.15 Fig A filling cycle showing additional double vacuum/gas flushing sequence.
and the ater wjet ws flomode into olumetric illing (Fig. the fsystems 7.11). bottle Vin full-
with a w flometer are the design of choice contact here, illing fsince by reason of the non-
.ebu ttne veh tr oebor p ahti wtcatno clacisyh po ns iereh tedom
these required, not is step pressurisation a and small, are ed olvvinements vmolift the As
time of amount the since output, same the for es alvvilling fwer fewith itted fbe can systems
deriuqer rof gnilaes eht elttob tsniaga eht gnillif evlav dna gnisirusserp ti nac eb yleritne
eliminated.
7.3.5 The filling operation
decaps era sreniatnoc eht :nesohc ssecorp gnillif eht fo tnednepedni si devlovni ecneuqes ehT
thguorb era hcihw ,selttob ssalg fo esac eht nI .hctip s(cid:146)rellif eht hctam ot deefni elttob eht ni
-moeg elttob eht ot dehctam ylesicerp smrow refsnart ,sroyevnoc lanoitnevnoc no rellif eht ot
eht stpecca leehwrats deefni eht ,decaps neeb evah selttob eht retfA .)61.7 .giF( desu era yrte
.noitisop refsnart s(cid:146)rellif eht ot ediug ydob a fo snaem yb meht stropsnart dna selttob ssalg
, where PET with bottles yor the are to illeraid eusually the of fed vfa through an air con
bottle infeed starwheel with controlled clamps, y theare passed into the machine. The bot-
tles in this case are guided by their neck rings, which has the antage advthat no handling
e to vparts be hareplaced for ferent running bottle difsizes. Only er when from vchanging o
xchanged.inish size to another does the transfer starwheel need to be eone neck f
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illing EquipmentBottle Manufacture and F 211
OC flushing
2
saG
Gas needle
Liquid stem
Vent tube
Liquid
Product feed channel
Snifting/CIP channel
Snifting/CIP valve
Snifting/CIP valve
. 7.14 Fig CO , by flushing the flushingPET bottle with ring bowl gas or pure gas the air content in the
2
.bottle can be displaced prior to filling
erugiF 51.7 setartsulli a gnillif ecneuqes gniwohs na lanoitidda elbuods ag/muucav
hsulf ing sequence:
7.3.4 Filling technology for non- carbonated products
bot-the pressurise to necessary not is it as systems, simpler using bottled be can ater wStill
for systems Filling wl. boring the in as bottle the in situation same the create to order in tles
still ater ware referred to illers, vimetric as as fgrathe product is passed from the wl ring bo
into the bottle without pressure, simply by the . force These of illing vityfgrasystems may
era dna ,evlav gnillif eht tsniaga elttob eht sserp ot tcatnoc lacisyhp yna tuohtiw etarepo osla
handling neck- a in machine the through passed are which bottles, PET for used particular in
gins, beoperation illing fthe e, alvvilling fthe under ed varrihas bottle the After iguration. conf
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214 aterechnology of Bottled WT
Filler
Capper
. 7.17 Fig iller and capper concept for high speed operation.F
Filler
Capper
Rinser
. 7.18 Fig - Monobloc set ., filler and capperup with rinser
the whereupon bottle, the on closure the places then head capping The starwheel. neck the at
closure is pressed onto the bottle by spring pressure and simultaneously wed screonto the
inish.thread of the neck f
with machines iller/capping rinser/fstanding free- use igurations confmachine raditional T
an yor einterconnecting vsystem conand controls. As line speeds , e verhavincreased weho
monobloc systems e vhabecome more commonplace. The introduction of the iller/capper f
system. monobloc iller/capper rinser/fa of elopment vdethe by wed follobeen has monobloc
Figure ws 7.17 a shotypical arrangement of iller/capper fsuitable for high speed operation,
iller/capper monobloc system.ws a typical rinser/fand Fig. 7.18 sho
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illing EquipmentBottle Manufacture and F 213
. 7.16 Fig .Infeed worm separating the bottles to match them to the pitch of the filler
At the transition point between the transfer starwheel and the , illerfglass bottles are
placed on a lift plate underneath the illing fe, alvvwhile PET bottles are held by a clamp
ring. As soon ed as e in ixthe been vthis bottles fy position, hastart theunderneath the neck-
pressed are bottles the , aterwcarbonated running When e. alvvilling fthe ards wtoraised be to
tsniaga eht gnirtnec tinu rednu e ehtvla gnilli nifv a thgitsag ,laes elihw rof llits reta yweht
are day merely illing fraised. systems Modern- for PET bottles designed for bottling still
ater wen vemanage to do without an grated intelifting unit , entirelysince the bottles are
el.viller at the same lepassed from the transfer starwheel to the f
w gins Nobethe illing , foperation which properas the el bottles varound trathe carousel
flushing, illing, pressurisation, settling fand snif-acuation/pre- vesubsumes the steps of pre-
bottles the wers lothen unit lifting The selected. process illing factual the on depending ting,
a to fed are y thewhere from ge, discharbottle the in starwheel transfer a to them passes and
.usually monobloc closer
7.3.6 Filler configuration
-ni hoedctheanttmiarg or, yesedea tlsebmananiirvlov tpnei cgnnoiclli g nneiohdtnfepeD
ydob -ngierof dna tsud yna evomer ot si esoprup yramirp stI .retaw gnilttob nehw ngised yre
sel cgintirdalpuom meonr ifwhcam ,se elsntitob htob ton ssalg dna TEP fi( a h c-twertsolb
detarg otentini eht enil ,)denrecno cgni wyb roolb gnihsulf meht .tuo sihT si dehsilpmocca
gnisu dloc , r,o , e lmirrae t, s,r idwaesri sentotain ardtiecateafwnnoizsoidriraeta row-utas
nwod -edispu eht syarps resnir eht ,slennahc owt ro eno rehtie gnirutaef yltsoM .maets detar
desilani sftipecn orcesn ier h.Tsnoit pdoetsil -evo bea hmto rafid eemer h o tpthut iswelttob
.noitanimatnoc fo secruos ot erusopxe (cid:146)selttob eht dna devlovni tuoyal enil eht tius ot
plastic for cappers synchronised directly capped: be to e vhabottles the illed, fbeing After
w screcaps on on closures PET and wns bottles crofor or glass for bottles, aluminium roll-
iller unit.grated into the fare usually inte
ia Vthe , sorterthe w screcaps (which are mostly the closure of choice for ater) ware
by heads capping the inside retained and e vabofrom capper the into fed and aligned spaced,
a holding feature. Bottles are simultaneously fed to the machine; glass bottles are secured
)sevink noitator -itna dellac( sekips yb selttob TEP dna ,leehwrats lartnec a yb gninrut tsniaga
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illing EquipmentBottle Manufacture and F 217
H14 air filter
roomClean
100class roomClean
1000class
Access door
PVC curtain or
plexiglass wall
Overflow
openings
Clean room floor Peak of the clean Overflow Overflow openings Operator panel
(1:50) floorroom openings towards the outside cleanthe outside
room
7.21 . Fig to filler the around air filtered of flow laminar the integrates filler the for design cleanroom A
avoid intake of microbiological contaminants.
handling appr optroi ataehnd ydeg siiegnnis c line(cid:146)the attot achbeed p mruisomtro irtey t he
conceorfn etdh.e packaging materials
In e particularly vareas, sensitiespecially where bottles and e caps vto habe stored prior
to illing, fsystem design has also been xtended eto cater for bottle and cap sterilisation.
ail-vaw noare systems illing, fbefore internally rinsed are bottles PET , traditionallyWhilst,
able to internally and xternally erinse bottles. In xtremely ee vsensitiareas, bottles can be
treated mentioned by disinfectants the AA e- vPabo(liquid) or H O .)suoesag( paC deef
2 2
to order In storage. of source xternal ean from machine capping the to caps er vdelisystems
violet complete the cleaning of the total package, cap feed systems can itted be with fultra-
lamps. Spraying systems for flushing out the caps with ozonated , aterwand also rinsing
systems with , ionised are airgetting more . or and Fsterilising more the popularw-caps, ho
, systems erailable vare vthat eatransport the caps through a sterilant disinfecting bath or a
treatment chamber with an H O enriched atmosphere. From - these cap disinfection units
2 2
placed on a platform e vabothe , illerfthe sterilised caps are transferred via a completely
y are applied to the bottle.enclosed chute to the capper where the
7.3.8 Monitoring and inspection technology
desimixaM gnilli ytilibailer .noitarepo si sihT suoira y laitnesse si snoitisopf rof yhwna tav
within the illing fsystem, monitoring or inspection units are installed, for erifying vthat all
functions are operating . properlyFrom the e vxtensierange of inspection units ailable, va
. If return-xamples will w be eselected, as only essential a for femonitoring product quality
able glass bottles are being run, it body is inspector advisable before to vide proa foreign-
y theare fed into the illing fsystem, and a detection system for residual cleaning chemicals
.asherged from the we been discharvafter returnable bottles ha
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216 aterechnology of Bottled WT
. 7.20 Fig In the hygienic filling design, the bottle is filled without any contact with the filling valve.
sys-disinfection bottle/closure and isolator an with conjunction in installed , illerfof design
e products.villing of sensititems, represents the optimum combination for aseptic f
A clean vireonnment around the ilfling process is just as important as a clean . ilfler
radiT,t ionallythe ilfling process has been separated from the rest of the ilfling line in a
(cid:145)clean(cid:146) area or room.e vlDoepments in this area ev haintroduced cleanrooms which, inte-
grally with the w nestyle of clean guard systems, fully surround the ilfling process. The
complete process, through rinsingi,l fling and capping, is housed in a cleanroom incorpo-
rating afns with microbial ilfters A). (HEPThe afns create a posevi tiairwf loinside the
ilflianrge wah,i evicnsht ilatatetodm eovcBlsryl.pe e wha letoaarvi teitn rhgeoi nnsm ent
ilfler A feeevc.fmt oirei s miitncip illarifmelnostiaidsc hsnan iteeerrgzhs doo ees ou ,mn d
cleanroomc anb es eeni nF ig.7 .21.aT rhieva nwtsn ch oonstitutesas tageevol fdo epment
between traditional ilflers (open design, no shielding against their surroundings) and an
aseptic model, which is protected from its surroundings by an isolator construction.
Products typically bottled on lines wiotzho tnhaitse d, l gaawetr ecrleanroom include non-
weakly carbonated spritzers or basesde nsevi tipromdiulckt-s for the cold chain. w Ho
bottle and closure hand ling is implemented in these solutions will depend on the charac-
tereivssl tiicosf atnhde dpersoidruecdt so levvds.h ienlfT-h e more sensevi tithe product,
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illing EquipmentBottle Manufacture and F 215
. Fig7.19 In an aseptic filling concept, the filler and its systems are completely separated from their
surroundings.
When handling and producing PET bottles with house an moulding stretch in- w- blo
or , illerfthe to bottles the transport to yor evconair an between choose can bottlers machine,
space-xtremely ean is This . illerfthe with directly moulder w- blothe synchronising BLOC-
eneigyh metsys fo level hgih a taht egatnavda rehtruf eht htiw ,noitarugifnoc enihcam gnivas
iller fthe to directly passed are bottles PET moulded w- blofreshly the since ed, vachiebe can
via an enclosed transfer starwheel system, without coming into contact with the outside
-ervbecarbonated for process illing fthe during bottles the stabilise to order In vironment. en
ages, this transfer section can also feature an grated intebase cooling system using ater w
flushing. The ater wused here can be recirculated for resource . economyA rinser is not
iguration.required in this machine conf
When PET bottles are being handled, adays wnoa labeller can also be included in the
monobloc iguration. confThe sequence here gins bewith production of the PET bottles in
moulding machine, wed folloby the , monobloc the which labellerstretch applies w- blothe
desired dress to the empty plastic bottles, after which the empty PET bottles are passed
iguration confmonobloc the inside systems rejection Suitable . illerfmonobloc the to directly
at the arious vpositions ensure that bottles tagged as e vdefectido not disturb the smooth
functioning of the monobloc unit.
7.3.7 Aseptic line concepts
proc-illing frun to possible it made also has systems illing folumetric vof elopment vdeThe
and illing fthe here Since 7.19). (Fig. surroundings their from isolated entirely are that esses
be thus can parameters illing fthe in changes , automaticallyfully actuated are es alvvcontrol
.entions from the operatory manual intervmade directly at the system, without an
can (cid:150) system cell weigh- a grating intemachines as well as (cid:150) generation this of Machines
when , particularIn conditions. sterile under processes illing fthe handle to equipped be also
es alvill illing without vthe bottles y touching can e the fstill fproducts, thevhandling sensiti
o Te. alvvthe with contact bottle from contamination of risk the minimises This 7.20). (Fig.
niag a reporp noitanimatnoced fo eht gnigakcap lairetam dna eht rotalosi secafrus diuqil
citecarep )AA dica roP( suoesag negordyh edixorepH( O ) are the chemicals in use. This
2 2
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220 aterechnology of Bottled WT
. 7.24 Fig Automated CIP cups close the filling valves to create a cleaning loop.
CIP systems are ailable vaas small modularised installations, which depending on the
elbairav A .noitarugifnoc desilartneced a ni rellif eht ot dengissa eb nac denrecnoc tuoyal enil
hot acid, caustic, , aterwbatch as such media, cleaning arious vthe for tanks batch of number
, aterwdisinfectant solution and fresh , aterwcreate a cleaning programme ely vresponsi
matched to the particular application. Cleaning agent concentrates can be dosed in from
concentrate packs or from a central chemicals ith store. the Waid of fully e automated alvv
dradnats a ,secneuqes demmargorperp dna ,sneercs -hcuot gnisu lortnoc rotarepo dna skcar ised
illers.vidualised cleaning programme can be created for the fut indib
7.4 OUR ADDITION VTION AND FLACARBONA
O FILLINGPRIOR T
suoesag evlossid ot yrassecen si ti ,segareveb retaw detanobrac ecudorp ot si noitnetni eht fI
CO in the product. This operation is ecuted xeprior to illing, fin . a The gree carbonatorde
2
of carbonation of bottled ater wis xpressed eas the ratio of absorbed carbon dioxide (CO )
2
represents ater wof litre 1 into absorbed dioxide carbon of litres 4 Thus, olume. vby ater wto
olumes.el of 4 vva carbonation le
Them aximuma mounto fc arbond ioxidet hatc anb ea bsorbedi sd ependentu ponp res-
sure and temperature, such that the higher the pressure and thwee lro the temperature, the
more gas can be absorbed. The basic principle behind all process arivants is that irfst of
aeratscittoaohenlnepsl ,t itouxeonynafigtn tesdrn o dgiawetstnhsei eor n le vd de-a ailnl ,
are reduced. This is accomplished alternevaltyi in a praeesrsautrieo n ors tep acuvum de-
or in a combined pressuareaerc/auvtuimo n dep-r ocess. The principle of pressure de-
aeration is based on adding CO iane ration a tank, de- so that air is displaced by CO .
2 2
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