Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry

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Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry
Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry
 Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry
Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry
 Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry
Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry
 Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry
Engineering & Fabrication of a Fruit & Juice Bottling System for the Beverage Industry

WEIGHTPACK, Inc. built this fruit juice bottling line for a customer in the beverage industry. Able to process both pulp-free and with-pulp products, this quadrablock machine was designed to meet the strict sanitary requirements of extended shelf life applications. We intelligently incorporated the four main components into a compact footprint, and the design represents state-of-the-art technology in terms of automation and ease of cleanability.

Operation starts in the sterilizing turret where each bottle is filled with an appropriate sanitizing liquid and held for a programmed amount of time. Next, the rinsing turret discharges the sanitizer and sprays the bottle with sterile water. Product is filled by means of a rotary net weight filler, with a small tank and perfectly laminar flow design that guarantee hygienic conditions are maintained. An electric capper completes the process. In-line sensors in the filler and capper detect flawed product and mark it for rejection. Fill volume and speed are programmable and vary according to product.

Constructed from 304 and 316 stainless steel with contact surfaces polished to a.02 micron mirror finish, the equipment is housed within a microbiologically isolated environment pressurized with sterile air that passes through 99.97% HEPA filters. Clean-in-place, sanitize-in-place, and spray cleaning of external surfaces are entirely automated.

To learn more about this project, or how our expertise at building net weight filling equipment for extended shelf life applications can improve your operations, contact us today.

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Highlights of this Fruit & Juice Net Weight Filler/Capper System:

Product Description
  • This Fruit and JuiceQuadrabloc is used to Bottle and Pack Fruit Juices with or without Pulp in an ESL environment
Engineering & Fabrication Capabilities Applied/Processes
  • Primary:
    • Design Engineering/Product Development
    • System Fabrication - Forming, Bending, Machining, Welding,
    • Electrical Engineering/PC program development
  • Secondary:
    • Assembly, Checkout, Shipping, Installation
Material Used
  • Stainless Steel 304 & 316
  • Plastic
Material Finish: Product contact surfaces
  • Polished to High Gloss - filler nozzle
  • 0.2 Micron Mirror Finish - inside product tank
  • Satin - exterior surfaces
Components
  • Quadrabloc for filling juice products requiring Extended Shelf Life (ESL)
    • Sterilizing Turret
    • Rinsing Turret
    • Rotary Net Weight filler in Ultraclean Version
    • Rotary Mechanical Capper (with foil lid sealer if requested)
Features
  • Rotary Sanitizing Turret to fill each bottle with the appropriate sanitizing liquid (Hydrogen peroxide, Oxonia, etc)
  • Star-Wheels Holding Section to assure the correct resident time
  • Rotary Rinsing Turret,to discharge the sanitizer and to spray sterile water up into the bottle
  • Ultra Clean Rotary Net Weight Filler
    • Small Tank is Shaped to give Hygienic Guarantees
    • Perfect Draining Capabilities
    • Perfect Laminar Flow Design
  • Membrane Nozzle (Laminar Flow)
    • Standard nozzle for most applications.
    • Laminar vanes built into the body of the nozzle
    • Easy changeover by changing diameter of removable disc
    • Easy to dismantle and visually inspect all product contact surfaces
    • Membrane separates moving parts from product flow
    • Pneumatic actuator
    • FDA materials only in product contact areas
    • Membrane duration life of 2 million cycles
    • Open/Close Nozzle without outside contacts
    • No dynamic Gaskets
    • Double barrier of separation between pneumatic actuator and product passage
    • No sliding friction in the product zone
    • Perfectly washable and drainable
  • All Moving Parts are made of Quality Materials
    • Long Lifetime
    • Low Maintenance
    • Wearing and Noise Emission
  • Extended Shelf Life (ESL)
    • Decontamination treatment of primary packaging by appropriate sanitizing liquids with electronically controlled valves.
    • Minimum log reduction for the containers/caps
    • ESL Filling Environment controlled by Air Laminar Flow obtained through HEPA ceiling filters in Ambient Class 100.
    • Filling operations performed with high hygienic standards.
    • Cleanability and drainability for CIP/SIP operations assured by an Ultra-Clean design.
  • ESL protections specifically designed to prevent dead zones or microorganisms harborage.
  • Electronic Capper - with option for foil lid sealer
  • Enclosure Pressurized with sterile air that passes through 99.97% HEPA filters.
    • 3-stages HEPA filters (U4-U9-U13).\
  • C.I.P. system, and sanitizers regenerating fluids skid
In process testing/inspection performed
  • Net weight cells under each container on filler turret record:
    • If empty container meets preset weight range
    • Exact net fill weight of every container
    • Any container not meeting standards is automatically marked for rejection
  • Sensors on capper turret sense missing or improperly applied caps and mark the container for rejection
Industry for Use
  • Orange and other juices requiring ESL processing
Volume
  • Fill volume and speed determined by pitch of machine selected to cover customer requirements
Delivery/Turnaround Time
  • An ESL capable Quadrabloc would typically require 6 months from finalization of all specifications and down payment to final shipment
Delivery Shipping Location
  • Either Goito, Italy or Powhatan, VA, USA depending on location of final customer
Standards Met
  • Customer Specifications, 3D CAD Drawing
Product Name
  • Fruit Juice Net Weight Filler/Capper

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