MODULBLOCK Rinsing, filling and closing technologies in one machine
Rinsing, filling and closing technologies in one machine
The virtually unlimited combinations allows the possibility to deliver to our customers a solution that will cater specifically for their bottling needs, enabling to process various types of containers and closures under one roof.
Perfect synchronism is obtained from one single machine drive having gear transmission or as an option through the use of brushless servo drives controlled electronically by the machine’s PLC.
The ModulBlock is available to suit the packaging of a wide range of products such as mineral water, carbonated soft drinks, wine, beer, edible oils, mixed alcoholic beverages, liqueurs, fruit juices, sauces etc, into traditional or modern packaging such as bottles made of Glass, Aluminium, PET, etc.
Our primary objective is in fact to care about “THE PRODUCT” making sure that its original characteristics are not altered through the filling and packaging process.
The rinsing turrets are manufactured with materials and technical solutions to the state of the art.
The rinsing machine typically mounted on the ModulBlocks is a rotary type and can be mechanical or electronic version.
The heart of the ModulBlock is the filling section. The choice of filling system depends primarily on the type of product to be filled, filling temperature requirements, density and Co2 content.
Counter pressure filling systems suitable for filling all kinds of carbonated and still products such as carbonated water, soft drinks, beer, etc.
This is featured by various different types of filling valve designs, from the traditional mechanical counter-pressure, to the most sophisticated electro-pneumatic system.
The traditional mechanical counter-pressure valve enables to carry out several phases such as pressurization, CO2 injection, multiple pre-evacuation, levelling and snifting.
The usage of the electro-pneumatic valve allow to carry out the same functions, but it is completely controlled and programmable from the operator panel. This allows the most up-to date technology and flexibility which is necessary to obtain high quality results and reduced risk of contamination.
Low vacuum-gravity filling systems are recommended for still, non-dense products such as for example still water, wine, alcoholic beverages (vodka, whiskey, brandy, etc), chemical products and generically any kind of flat non viscous liquids.
Various models of filling valves are available within this category, specifically designed to cater for the filling level requirements, bottle shape, neck shape and product.
Several optional features are available such as the “millimetric adjustment of the filling level” controlled directly from the user interface panel, air return outside the filling tank (to avoid the air from the bottles contaminating the product in the filler bowl), centralized level regulation and more.
Electronic Flow Meter
Electronic flow meter filling system.
These systems assure maximum dosing precision and do not require any maintenance.
Thanks to the extremely small number of functional elements, the filling machine can be sanitized very easily and the Electronic Volumetric filling allows optimized filling under a microbiological profile.
The system works without pressure in the bottle and with a light positive pressure inside the filler bowl, allowing to process both high density and liquid products in containers of different materials.
The filling is controlled by the PLC that gives the go-ahead to start the filling when the sensor detects the presence of the bottles.
The electronic dosing devices with mass or magnetic flow meters show that the preset filling volume has been reached and control the closing of the valve, allowing a dosing precision of 0,2%.
As a result we obtain a precise volumetric filling and a microbiological safety.
Volumetric (or piston)
Volumetric (or piston) filling system guarantees that the container is filled with an exact quantity of product, having a maximum tolerance of +/- 1,5 cc using 1 litre cylinders.
This result is obtained regardless of the product’s thickness and of the differences in actual capacity between containers of the same type and size.
Therefore piston filling is the correct choice for applications where accuracy of actual volume contained in the bottles is important, or in case of filling dense products into plastic containers.
The filling system consists in two steps: during suction, the product passes from the tank to the metering chamber through a three-way valve which measures the product thanks to its piston-based operating principle, according to a preset quantity.
To empty the chamber, the three-way valves activates a pneumatic valve controlling the piston: the product is pushed out of the cylinder into the container.
It is possible to adjust the filling speed in the top portion of the container, where the neck must be filled slowly to prevent foaming or spillage.
Net weight filling system is used for various types of still products including thick and viscous liquids, such as vegetable oils, detergents, liquid soaps, etc into containers of any kind including soft plastic material such as PET or HDPE bottles.
The advantage of this system is that is very gentle on the product and allows extremely precise net weight measurement, regardless of the empty container weight variation.
High Vacuum filling is used for thick and viscous liquids, such as vegetable oils, syrups, sauces, etc into containers which are resistant to vacuum, such as glass bottles.
As opposed to the gravity or low vacuum system, the filling takes place by creating a vacuum inside the bottle through a separate channel, allowing the product to flow from the filling tank more easily.
At the end of the filling process, once the desired level has been reached, any excess product is collected into a dedicated reservoir on the ground and sent back to the main tank or managed according to the customer’s requirement.
The intensity of the vacuum is adjustable to suit the product density and the production speed.
Positive Pressure filling system is used for thick and viscous liquids, such as vegetable oils, syrups, sauces, etc into containers of any kind including soft plastic material such as PET bottles.
As opposed to the gravity or low vacuum system, the filling takes place by creating a positive pressure inside the filler bowl, allowing the product to flow from the filling tank to the containers more easily.
Hot filling system suitable for juices and isotonic beverages.
The principle of operation is similar to the gravity-low vacuum system, however the machine and its filling valves are designed to allow product recirculation in the tank and in the filling valves themselves in order to keep the constant filling temperature even in the eventuality of a machine stop.
With the hot fill technology it is possible to fill up to 90°C, guaranteeing a constant filling temperature and filling level accuracy.
The ModulBlocks can be equipped with one or more capping turrets, allowing to be able to process multiple closures with the same machine, thus increasing its versatility.