KRONES Akademie

Lifecycle Service
Contipure AseptBloc DN
Service Training

Introduction

Erstellt von: Academy Plastics Division

Datum: 02/2020
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Disclaimer

▪ This presentation was exclusively created for the purpose of training in the KRONES
Trainingcenter and doesn‘t possess general validity.

▪ The Technical Documents (TDs) and guidance documents are to be treated as the primary
sources of information and must be applied as such.

▪ This presentation reflects the technical standard at the point of its creation, there is no
binding obligation to continuously update the information contained or to gather every
unique series version. The approach to some technical tasks may vary, depending on the
series version.

▪ Specific information like the necessary torque, use of Loctite etc. must always be taken
from the most recent production drawings.

▪ The company-wide general safety guidelines must be adhered to at all times.

▪ Date: 01.06.2017
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Systemportfolio AFT

Why?

Extend the shelflife without usage of preservatives

(for sensible Products)

But what is a sensitive product?

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The Ph-Value

7,35 – 7,45

Acid Area Water Basic Area

7
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Microbiological sensitivity of beverages

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Portfolio Aseptik in der AFT

Preform treatment Bottle treatment

C3-Pro Contiform Asept

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PET Asept L2

PET Asept D

PET Asept D
Compact
Contiform
AseptBloc [H2O2]
Contiform
AseptBloc [PreBeam]

Contipure D
Bottle Preform Low Acid High Acid Dry Isolator Wet Isolator Filling Valve
Sterilization Sterilization Sterilization Sterilization Steamable
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PET Asept L2

Bottle Preform Low Acid High Acid Dry Isolator Wet Isolator Filling Valve
Sterilization Sterilization Sterilization Sterilization Steamable
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PET Aseptic L2.1 – Bloc Principle

Bottle outlet
Preform infeed

Decontamination Bottle rinsing Filling Capping

◼ Sterilisation of ◼ PAA residues < 0,5 ppm ◼ Aseptic filling ◼ Krones aseptic servo
bottles by PAA ◼ Rinsing with sterile water capper
◼ Highest mechanical
07/2013 China Market

- Interior to remove sterilant

- Exterior and hygienic
performance
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Sterilizer_Internal Bottle Treatment

▪ Well approved and reliable basic operation principle

➢ Mixing of PAA and food grade steam in one nozzle
➢ Steam as carrier and activator for PAA
➢ Additional to sterilisation: washing effect removes
dust particles

▪ Stainless steel clamps for neck handling

▪ Hygienic design
steam PAA

• Advanced version of a well established

decontamination technology
• Efficient treatment of sensitive critical areas at
bottle neck
• Technological principle well approved from H2O2
07/2013 China Market

dry aseptic
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Sterilizer - External Bottle Decontamination

▪ Bottle Internal Treatment : PAA + Steam

▪ Bottle External treatment : PAA ( <45 °C )

➢ Cooling down the bottles heated from internal
treatment

▪ Bottle External Treatment : PAA

➢ Only exterior up to 60°C

▪ Exterior bottle treatment with high concentration

PAA – but low consumption.

▪ More efficiency bottle external decontamination.

07/2013 China Market

▪ No use of surfactants, water recycling possible

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PET Asept L2 – Section: Rinser

One-Channel-Rinser
No CIP-Cups
Open SIP into the Isolator

PAA-recovery from sterilizing

process

Re-designed nozzle for a

better rinsing effect without
jetting

Reduced water consumption

Reduced time for cleaning

and sterilization
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Cap Asept L – PAA Cap Disinfection

▪ Decontamination of submergible caps in
disinfectant bath (PAA)
▪ Fully-automated process
▪ No moving parts, caps are moved forward by
disinfectant flow
▪ Temperature and PAA concentration continuously
checked
▪ Flushing with sterile water and drying with sterile
air

▪ Approved decontamination concept

▪ Reliable & reproducible germ reduction
▪
07/2013 China Market

Straightforward operation
▪ Exceeds FDA standards for residuals
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PCS – Process Control System

Aseptic
Bloc CIP-
Ventilation
▪ All the machines involved in aseptic Plant
process linked in terms of:
▪ Signal exchange
▪ Data exchange
Reverse- Hygiene-
▪ Communication
Osmosis center
▪ Links to 3rd party machines possible

▪ Data connection to LDS (line Liquid Sterile-

documentation system) possible Nitrogen Water
Dosing UHT

Food grade
Thermal
07/2013 China Market

Steam Mixer
Generator Product
Treatment
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PET Asept L2.1: Summary…

STERILIZER RINSER FILLER CAPPER

High Perfomance 1-Channel Execution
Sterilization Of The Bottle Product Feed From Top
With Separate, No No Use Of CIP Cups Totally Modified Capper
Slipring Distributors
Sterilizing Carousel High Efficient Spraying Hygienic Discharge Belt
Sterilization over Filling Valve Steamable
Starwheels Recycling Of PAA
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PET Asept D

PET Asept D
Compact

Bottle Preform Low Acid High Acid Dry Isolator Wet Isolator Filling Valve
Sterilization Sterilization Sterilization Sterilization Steamable
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PET-Asept D – Bloc Layout Example

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PET-Asept D – Completely Dry Decontamination Process

Bottle
Decontamination Blow out
conditioning

The bottle is rinsed with a Blow out of bottles after

Bottles are rinsed with warm sterile air to
mixture of vaporized decontamination to reduce
equalise temperature within bottle (esp.
hydrogen peroxide (VHP) residuals down to ≤ 0,5 ppm.
bottom and neck area)
and sterile air.

Warm H2O2 gas is applied to warm bottles – No condensation at all!

→ Fast and efficient degermination process
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PET-Asept D – Bloc Overview

Blow moulding machine

Bottle conditioning

Bottle decontamination

Bottle blow out (warm)

Bottle blow out (cold)

Aseptic filler

Cap disinfection unit

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PET-Asept D – Basic Principle, NO Condensation

Bottle surface
◼ H2O2 solution is ◼ H2O evaporates ◼ Gaseous H2O2 ◼ Cells are killed
sprayed on due to lower has access to cells completely
surface evaporation → Effective killing
◼ cell is covered temperature than process starts
and sealed H 2O2
◼ H2O2 solution → H2O2 conc.
with little killing increases, killing
efficiency effect increases

Viable Microorganism
H2O2 drop (liquid) The KRONES gaseous H2O2 process:
H2O2 atmosphere (gaseous) Simple And Effective
Energy input (heating)
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H2O2 – The visible Difference

− Bottles are preheated – warm bottle surface

− Application of gaseous H2O2 (no condensation) for interior
bottle treatment
− Bottle exterior decontamination by H2O2 atmosphere inside
the isolator room
− Removing of H2O2 by warm sterile air
− Cooling of bottle with cold sterile air

◼ Truly dry process without condensation

◼ Low permeation of H2O2 into PET material
KRONES and H2O2 condensation
→ residues < 0,5ppm
◼ Effective and fast germ reduction
◼ Gentle bottle treatment
◼ Low media consumption
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 PET-Asept D – Cap Sterilisation with vaporized H2O2

− Simple mechanical design

− Short treatment time at higher
temperatures
− Last bottle – Last closure

− Used in all completely dry systems:

− PET-Asept D
− PET-Asept D Compact
− Contiform AseptBloc
− Contipure D
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New cap sterilisation with a simple, reliable and robust design

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Discussion: Process window for sterilisation process with bottle decontaminatinon

Process window
Bottle
sterilization Permitted
Required count residuals
reduction

Bottle sterilisation: Values for Shrinkage of

◼ Shrinkage bottles Shrinkage influenced by
• Preform (form and resin)
◼ Residuals • bottle design
◼ Count reduction • blow moulding process
have to be in compliance
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Contiform
AseptBloc [H2O2]

Contiform
AseptBloc [PreBeam]

Contipure D

Bottle Preform Low Acid High Acid Dry Isolator Wet Isolator Filling Valve
Sterilization Sterilization Sterilization Sterilization Steamable
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Contipure AseptBloc (DN) – Sterilization (internal + external)

VHP
VHP
Steam VHP
VHP

VHP
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Benefits Preformsterilisation with Contipure DN

• No thermical Bottletreatment

No Shrinkage
Process window
Preform
No Relax Process needed sterilization Required Permitted
count residuals
Lightweight possible reduction

• Lesser residual H2O2-Concentration

• Bigger process Window concerning treatment temperature and H2O2-

Concentration

• Lesser Media consumtion

• Only the Preform must be Validated not the Bottle

• Simple shape for sterilisation

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Animation
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System description Contiform AseptBloc

Cap sterilisation

Aseptic blowing module

Infrared oven

Preform sterilisation
Preform feeder
Aseptic filler & capper
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Relevant data fair machine

Machine output: 55.200 Preform-sterilisation Ventilation technology

Treatment starwheel 3x Ø720mm Central ventilation technology
bottles/h Nozzles per starwheel 22 Sterilisable HEPA filters
Gaseous H2O2
Bottle volume: 500ml (reference) CIP-connectivity
Blow moulder CIP module integrated in the filler
Contiform A24
Products: Blowing stations 24 Production time
▪ Mixed milk beverages Up to 144 continuous hours
▪ UHT-Milk Filler
▪ Juices Teilkreisdurchmesser 2160mm
Cleaning
▪ Tea/Ice tea Teilung 103mm [last bottle– first bottle]
▪ Energy Drinks Anzahl der Füllventile 66 ≤ 2,5 hours
▪ Particle-containing beverages
Isolator cleaning COP
Cap sterilisation Caustic acid cleaning
4 tracks
Sterilisation agent H2O2 Isolator sterilisation SOP
Gaseous H2O2
Capper
Pitch diameter 720mm
Filler sterilisation SIP
Hole pitch 103mm Food-grade steam
Capping heads 22
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Preform feed & Contifeed RS – model „Clean Design“

▪ Storage silo, vertical conveyor and roller sorter ▪ Preliminary cleaning with ionized air in the preform rinser
in the Clean Design (PreJet) and pre-control for eventual damages in the
control unit (PreformCheck)
▪ All components are kitted with plexiglas covers
▪ Immediate ejection of faulty preforms
▪ Integration of a pre-treatment zone in the preform
feed ▪ Subsequent transport of the preforms through a closed off
feed rail to the infeed area

Vertical conveyor

Roller sorter
Preform silo
PreJet

PreformCheck
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Heating module

▪ Almost identical heating module Contiform A to the Contiform 3 Standard

Series

▪ Determination of the size of the heating module according to the output and
the geometry of the preforms

▪ Chain pitch heating module Contiform A,

usually at 50 mm (wide-neck preforms)

▪ Air filtration of the Neckfinishcooling

▪ Tolon-camfollower on the contorlhead

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Preform sterilisation module

▪ Preform sterilisation module is blocked in between the heating

module and the blowing module of the Contiform A

▪ Usage of gaseous hydrogen peroxide (H2O2) for spotless

preform sterilisation

▪ Reaction of the gaseous H2O2 with the heated preforms (at

roughly 100° C warm sterile air)

▪ Decay of the treatment gas after extraction in the components

water (H2O) and air(O)

▪ in future the exchange of the preform sterilisation module for

a PreBeam module is possible
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Preform sterilisation

▪ Preform is ready for dry sterilisation after

contribution of the necessary temperature profile

▪ Injection of gaseous hydrogen peroxide (H2O2) into

the interior the preform

▪ Simultaneous flow around the exterior of the

preform through the H2O2 atmosphere in the
sterilisation module

▪ Finished construction and exact ventilation prevent

spreading of the sterilisation agent in the blow
moulder machine
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Contiform A – aseptic blowing module

▪ Stretch blow moulding under aseptic

circumstances

▪ Blowing wheel is secured against the

„microbiological grey zone“ with content lock

▪ Stretching rod doesn‘t leave the sterile zone

throughout the whole blow moulding process

▪ Air guide: blowing module is impinged with

overpressure; conditioned air prevents
condensation in the area of the blowing wheel

▪ Every component used in the blowing process

are completely sterilisable
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Mould concept & mould exchange

▪ Mould concept Contiform A is different to Contiform 3

▪ Outer diameter (mould concept!) 135 mm (CA++ 150mm)

▪ Maximum value of containers:

Volume 2,35 l / Ø 105 mm CA++ 120mm / Height 329,5 mm

▪ Mould exchange only at one point in the blow mould machine for
hygiene reasons

▪ Exchange time of moulds and handling parts depends on the

number of stations and customer objects

▪ Automatic mould exchange system will most likely not be

included – there is a quick mould exchange system available

Mould hanger (stainless steel)

Mould (aluminium)

Gasket
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Blowing module – air guide and ventilation technology

▪ Constant atmospheric overpressure inside of the

blow moulder

▪ Protection from dust particles and from carryover

of the hydrogen peroxide from the sterilisation
module

▪ Constant air exchange on the inside of the blowing

module for consistent, clean air quality
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Difference of the Contiform AseptBloc compared to common aseptic applications

Contiform AseptBloc 17 x 8 m (136m²) @ 32.000 cont./h Wet aseptic: 17 x 12 m (204 m²)

Contiform AseptBloc 14 x 6,5 m (91 m²) @ 24.000 cont./h Dry aseptic: 19 x 8 m (152 m²)
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Aseptic filler

▪ Through a transfer area the sterile bottle

reaches the filler

▪ The product feed assembly at the filler

happens from above with a steam-locked
sliding ring distributor

▪ Depending on the filling system used, particle-

rich beverages with fruit chunks up to
10x10x10 mm may be filled (filling tests will be
necessary)
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Aseptic capper

▪ The new Krones Aseptic Capper is consistently

carried out in the Hygienic Design version and
fulfills the highest possible hygiene standards

▪ The cap retainer is designed in an open way

and easily cleanable – movements of the
capping head are sealed through bellows

▪ Depending on the performance a handling

free capper outlet and a height-adjustable
discharge conveyor will be fitted
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Capper – processing

▪ The capper sorting on the Contiform

AseptBloc happens through the sorter

▪ The Krones SmartCam inspects the caps after

sorting

▪ The Krones cap buffer system takes care of

sufficient buffer capacity if the Bloc has to be
emptied for example

▪ The cap decontamination in the Contiform

AseptBloc is conducted through gaseous H2O2
in a linear fashion

▪ To realize higher machine speeds even on

short stretches, the cap sterilisation occurs on
several lanes

▪ At the end of the sterilisation area the caps

are brought back together
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System advantages Contiform AseptBloc

Contiform
AseptBloc

Filling „to the last drop“, due to a sophisticated control system the last product can Produkt-
Sicherheit
be filled into the last bottle using the last cap
Product Safety

Wirtschaft-
Ökologie
lichkeit
Ecology
Profitability
The isolator air is not only filtered but also conditioned.
Formation of condensation in the isolator is impossible due to this Krones
Aseptik

Bediener-
Zuverlässig-keit
freundlichkeit
Reliability
Usability
No sterile water UHT and no hygiene center are necessary
Verfügbarkeit
Availability
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System advantages Contiform AseptBloc

Contiform
AseptBloc

Produkt-
The filler comes with its own CIP module Sicherheit

Product Safety

Wirtschaft-
Ökologie
lichkeit
Ecology
Profitability
No manual procedures are required when changing the set on the filler1
Krones
Aseptik

Bediener-
Zuverlässig-keit
freundlichkeit
Reliability
Usability
The incidental blowing air can be recycled using the Air Wizard
Verfügbarkeit
Availability
[1] At an output of 24.000 bph.
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System advantages Contiform AseptBloc

Contiform
AseptBloc

Minimal peroxide residues as the preform sterilisation with subsequent surface Produkt-
Sicherheit
enlargement entails strong dilution effects
Product Safety

Wirtschaft-
Ökologie
lichkeit
Ecology
Profitability
Due to the preform treatment system, Lightweighting is possible without
limitations Krones
Aseptik

Bediener-
Zuverlässig-keit
freundlichkeit
Reliability
Usability

Verfügbarkeit
Availability
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System advantages Contiform AseptBloc

Contiform
AseptBloc

Produkt-
144 hours of continuous production time Sicherheit

Product Safety

Wirtschaft-
Ökologie
lichkeit
Ecology
Profitability
The aseptic process is based on the FDA certified sterilisation method for the
sterilisation with hydrogen peroxide Krones
Aseptik

Bediener-
Zuverlässig-keit
freundlichkeit
No need for any water in the production mode „no water – no life“ means that Usability
Reliability

there will be no sustainable habitat for any microbiological life

Verfügbarkeit
Availability
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Portfolio Contiform Asept

May a pitchadjustable transferstar is needed!

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