LINEAR FILLING HP
FILLING WITH ELECTROPNEUMATIC VALVE
The filler turret with electropneumatic valve may work at atmospheric, light or high pressure. The working pressure can be adjusted from the control panel and can vary from 0 to 8 bar. This feature allows the ideal canning of still, sparkling and champagne products. The linear design applied to small size monoblocks allows to have an higher productivity comparing to the rotative solution. Furthermore, GAI improved this configuration in order to simplify circuits with no compromise on the process quality. The filler tank is made from a high-thickness pipe obtained with precise machining for shaving removal. Then it is mirror finish polished internally. This solution allows to have a filler tank weldings-free, mechanical strength optimized and fully comply with alimentary regulation requirements. The small tank volume (from 10 to 22 liters) minimize product losses on the beginning and end of production and make easier the filler sterilization.
1. FLEXIBLE FILLING
This valve is suitable for bottling without compromise still, sparkling and champagne products. All the operating parameters: vacuum in bottle, working pressure (from 0 to 8 bar), degassing procedure are set on the control panel and can be changed with no manual intervention. Bottling can be carried out under optimal conditions since oxidation is minimized and maximum sterility is guaranteed.
2. LEVEL ADJUSTMENT
Centralized level adjustment, with a 25 to 100 mm adjustment range. The valve have been designed to ensure precise filling height and tolerance is reduced (1 mm) by using the automatic levelling device.
3. STRUCTURE WITH DOUBLE TUBE WITH LOWER CLOSING
The filling and return gas tubes closure placed on the bottom parts of the valves ensures precise filling level even without using the auto-levelling device. This structure brings remarkable advantages during the degassing phase since the perturbation caused by the degassing of the product in the gas return tube is completely eliminated. This increase substantially the production working with high carbonated product.
4. AUTOMATIC DUMMY BOTTLE
For the filling valve sterilization a dummy bottle with manual insertion is provided in the standard supply. Dummy bottle allows to perfectly sanitize the filler since it generates a circulating flow around the filling valve.
5. SECURE STERILIZATING CYCLE
The electro-pneumatically actuated valves, together with the dummy bottles, guarantee effective and well-defined sterilizing cycles. The process improves sterilization, but also ensures for it to be securely carried out on any circuit on the filler. The machines could be linked to an automatic CIP system so the sterilizing cycle can be carried out without supervision.
6. PRESSURE TRANSDUCER
The pressure transducer on each spout controls that the filling cycle is carried out correctly. It also detects any anomalies or malfunctions. These controls allow detecting for instance: insufficient vacuum degree, exploded bottle or missing seal on the cone, pressure trend during degassing, top seal unscrewing.
7. OPERATING CYCLE ITERATION
The filling cycle managed with timing phases can be personalized according to the type of product to be bottled and it ensures maximum production repeatability. This enhancing work quality as well as productivity.
8. BOTTLE PRESENCE CONTROL
The bottle is seen by a photocell at the monoblock entry. After this first reading, a second signal is sent by a proximity assembled on the bottles lifting piston. The two signals allow the start of filling cycle.
9. FORMAT SAVING
The filling cycle is set through the control panel. Saving cycles and recalling them simplifies and speed up the changing format operation. This guarantees a more uniform production.
Centralized level adjustment, the universal screw and the automatic electrical height adjustment on all turrets allow to have an extremely quick and precise changeover.