KHS delivers flexibility and resource-efficiency to blooming sensitive beverage market

11 Aug 2020 --- KHS has introduced a linear InnoPET BloFill ABF aseptic block to satisfy the requirements of the dairy industry for flexible filling technology for sensitive products. With fast format changeovers and a modular design, the German filling and packaging systems specialist delivers a flexible solution to the rapidly changing demands of the “flourishing” sensitive beverage market. Globally, dairy manufacturers have recognized the potential of wholesome beverages and expanded their product portfolios, often filling new products in PET bottles.

Sensitive beverages include juices, nectar, still drinks, tea, milk, milk-based drinks, yogurt drinks and other liquid dairy products made out of oat and soy.

Sensitive beverages are becoming increasingly popular worldwide, and the demand for functional foods with less sugar, in particular, is growing. “Keeping to a healthy diet plays a central role in the lives of more and more consumers,” explains Thomas Redeker, Global Product Account Manager at KHS. “The demand for products that are sustainably packaged and attractively presented has also greatly increased in the last few years.”The heating system consumes up to 40% less energy compared to most standard alternatives.

“PET is 100 percent recyclable, unbreakable, reclosable and it protects the product very well. Due to KHS’ Plasmax barrier technology (PET bottle with a thin glass layer inside), PET bottles are perfect for oxygen-sensitive products. Our new line can also integrate bottles made of up to 100 percent recycled PET,” Redeker tells PackagingInsights.

PET bottles also boast the capacity for individual design. “PET bottles lend themselves to exclusive design. The cap and label can also be perfectly tailored to the brand. This had a positive effect on the brand positioning at the point of sale,” he adds.

Cutting energy and costs
KHS first recognized the potential of PET containers for aseptic filling 25 years ago. Its latest development is the linear InnoPET BloFill ABF aseptic block, which combines the rotary InnoPET Blomax Series V stretch blow molder with the linear Innosept Asbofill ABF 712 aseptic filler.

The linear Innosept Asbofill ABF 712 filler for sensitive products is available in a standard aseptic and an ESL version.The block yields take up less space than the individual machines and, significantly, the air conveyor is no longer required, cutting energy consumption. Another advantage is that personnel costs are reduced as only one operator is needed in place of the former two. “By blocking the machinery and including a continuous clock module, we also minimize the risk of soiling. This has a positive impact on hygiene and line availability,” explains Redeker.

Fast format changeovers
Fast format changeovers within 10 minutes help boost system availability, which are performed under aseptic conditions, removing the need for additional cleaning and sterilization. The short changeover times also let producers fill a large number of different stock-keeping units quickly.

The linear aseptic block is designed to fill milk, mixed milk beverages, juice, smoothies and iced tea into PET bottles, holding between 250 ml and 2 L. The equipment outputs up to 12,000 1 L bottles and a maximum of 14,000 0.5 L bottles per hour.

Bottlers also profit from the modular design of the dry aseptic block, which allows the filler to be expanded at any time. Operators can retrofit their block with a chunk filler or additional filling and capping unit, for instance. “The modular design gives our customers greater flexibility. They don’t have to think about precisely which products they want to bottle when purchasing the block,” Redeker says. “KHS enables them to retrofit the required modules on-site as soon as they expand their product portfolio.”By blocking the stretch blow molder and linear filler, KHS minimizes the risk of soiling.

Near-infrared heating technology
With the integration of the stretch blow molder, the aseptic block gains several further plus points. One of these is that the heating system in the new Blomax generation consumes up to 40 percent less energy than most standard heating systems due to its optimized near-infrared heating concept and new Double Gate technology. The system is made possible by the near-infrared heater centrally installed in the closed reflector tunnel.

In the heater, the preforms pass the centrally arranged heating units to the left and right. The preforms are spaced around 18 ml apart instead of the previous 37 ml. The Dortmund systems supplier has thus been able to reduce the number of heater boxes used significantly. The air management system for heater box ventilation has also been optimized. “The fan can be set separately for the neck, reflector and lamps. This means that the machine only cools the areas which need cooling,” explains Redeker.

Effective sterilization
When further developing its linear aseptic filler, KHS focused on increased efficiency. The filling machine for sensitive products is available in both a standard aseptic and an ESL version. In the KHS process, sterilization takes place in several stages. First, the machine disinfects the neck and bottle interior. Here, the inside of the container is sprayed twice with a hydrogen peroxide aerosol (H2O2) at a speed of up to 80 km an hour. “This ensures that every part of the bottle is sprayed and sterilized; we even achieve this with individual designs and critical shapes,” Redeker says. Secondly, two aerosol reaction cycles are initiated. The process ends with a four-stage drying process that uses sterile hot air.KHS’ linear InnoPET BloFill ABF aseptic block is designed to fill milk, mixed milk beverages, juice, smoothies and iced tea into PET bottles.

Gentle filling for product protection
To ensure the quality of the products, the aseptic zone must be completely clean. KHS ensures this in part by gentle non-contact filling performed in two stages, preventing any excessive beverage foaming.

After filling the bottle is conveyed to the capping unit. Here, the closure is sterilized in the same manner as the bottle in the filling section. The process entails two-step disinfection with H2O2 and two drying stages with hot sterile air. “In the capper unit, we’ve also made sure that all parts in the aseptic zone have a flat surface. By doing so, we can prevent any air turbulence, making cleaning and disinfection easier,” notes Redeker. The bottle is then dated for full documentation of all information. “Our customers can always see which product was filled when on which valve,” he concludes.

By Joshua Poole