1143_acf - dry sterilization

8/12/2019 1143_ACF - Dry Sterilization

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ACF* The Futu re Techno log y

Offe red by KHS Alfil l Toda y!

ACF = Aseptic Cold Filling


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Taking the Lead by Setting the Trend 4

Aseptic and ESL Products*

A System Concept for Tom orrow s M arkets 5

KHS Innosept ACF Dry Steri l ization

A New Dimension in Aseptic Cold Fil l ing. Exclusively from KHS, w orldw ide! 6

A Revolut ion! Plastic Bott le Steri l ization Entirely Witho ut Water

Take Advant age of the Cutti ng Edge of KHS Alfi ll Technology 7

Greater Freedom for New Product Ideas

The New KHS Alfill ACF Generation with H 2O2 Sterilization 8

The Heart of KHS Alfill ACF Technology

Innosept, the M odular Concept System 10

Precision Down to the Last Bottle

For Carbonated and Non -carbonat ed Beverages 12

Gett ing into t he Thick of I t

By-weig ht Dosing Filling System 13

All-in-One Solution

Innosept LINEFILL - The Compact Linear Filler Solut ion at up to 6,000 Bott les/h 14

Sterile at a Low Price

Perfect Screw-cap Sterilizat ion 16

Innofil l SV Asept ic Screw Capper

The Mister Clean of Cappers 18

Constructed in KHS Hygiene Design

No Lubrication in the Sensit ive Bottle M outh Area 19

From t he Raw Product to the Capped Bott le

Com plet e ACF Technology 20

Microbiological Safety

CIP/SIP Technology w ith Sanit izing and Disinfection Cycles 21

Validation Acceptance Support

KHS Is and Remain s Your Part ner 22

AIS KHS Plant Information System

A M ust for Aseptic Fi l l ing 23

Th e i n f o r m a t i o n c o n t a i n e d i n t h i s b r o c h u r e i s n o n - b i n d i n g .

O n l y the techn i ca l spec i f i ca t i ons o f ou r quo tes a re de te rm ina t i ve w i th r ega rd to des ign and scope o f de l i ve r y .

S ub jec t to des ign mod i f i ca t i ons .

* ESL = Extended shelf life


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Taki ng th e Lead by Sett ing th e Trend

While dry steril ization is convincing on the one hand due to

the addit ional cost-cutting aspect of using less r insing wat er

for bot t le and closure t reatment, the w et method on the ot her

hand is compelling in particular because of the bottle and

closure rinsing process.

The dry steril ization m ethod is the preferred metho d if t he user

can guarantee that t he containers supplied are dry and free of

particles.

The ACF technology from KHS provides you maxim um production

and product safety and creates the ideal condit ions for aseptic

fi l l ing of non-carbonated mineral wat er, fruit juices and fruit

drinks, iced tea and w ellness drinks, as w ell as dairy and mixed

milk drinks for today's products and tomorrow's markets.

It is even possible to bott le carbonated beverages such as

spritzers.This means a safeguard for th e future fo r new product

developments as well.

The trend towards healthy nutrit ion develops the markets

of the future. Natural products are in demand. Sport , energy,

fitness, w ellness are terms that stimulate consumption .

M ore and more no n-carbonated beverages and sensit ive

products are being offered in plastic bottles. Innovative ideas

are needed in order t o f i l l these products aseptically safely

and economically.

KHS has developed and convincingly put these ideas into

practice.

With its latest generation of dry bottle and cap steril ization with

H2O2 and the w et ster il izat ion method w ith peracet ic acid, KHS

offers tw o m odern and reliable systems in its ACF program.

From a hygienic safety standpoint, both m ethods definitely

behave identically. The decision in f avor of dry or w et steril ization

can be made individually b ased on prevail ing op erating

conditions. This includes the quality of the bot tles and closures,

their conveying condit ions, and of course the range of beverages

to be fi l led.


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Non-carbonated water

Carbonated water

Mi lk

Flavored milk

Vegetable juices

Coffee and milk

Tea and m ilk

Orange juice

Tea

Sports drinks

Apple juice

Spritzers

pH

High acid Low acid

2 3 4 5 6 7 8

Spectrum of pHs of beverages to be fi l led

Aseptic and ESL Products

A System Concept for Tom orrow s M arket s

Cold aseptic filled products are capturing markets.

Thanks to t hese advantages:

Preservation of product naturalness.

No lo ss of valuable ing redients and flavors.

No preservatives.

No de gradation of quality caused by hot f i l l ing.

All shapes of at t ract ive, l ightweight , inexpensive p last ic

bottles can be processed.

The focus is on popular convenience characteristics

and cost benefits.

The Innosept ACF dry steril ization m ethod using hydrogen

peroxide (H2O2), a mini- isolator for the steril izer, activator,

and fi l ler as w ell as cap steril ization and an aseptic

capper are special technical features from a sole source.

Available exclusively from KHS Alfi l l .

You save on the cost of investment , fresh w ater,

and wastewater in addit ion to saving space.

You can process a wide variety of products on a

single KHS Alfill ACF line.

Pure flexibility!


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Ster i le room and mini - isolator

1 Fil l ing valve

2 Stat ionary f i l ler zone

3 Mini - isolator

4 Rotat ing f i l ler zone

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KHS Inno sept A CF Dry Steril izatio n

A N ew Dim ension in Asept ic Cold Fill ing.Exclusively from KHS, Worldw ide!

Patented m ethod of dry bott le and closure steril ization.

Reliable and proven H 2O2 technology.

Drastic decrease in operating costs.

No water consumption for the bott le steri l ization

process; no w astewat er.

M inimal sterile zone for t he entire process.

M ini- isolator t echnology for bott le steri l izing and

filler/sealer.

Trend-settin g concept for compact and hygienic machine

design.

Smal l footpr int , opt imum use of f loor space, ease of

operation, effective cleaning and disinfection.

High biolog ical safety and reliabil ity.

Ideal for non-refillable PET and HDPE containers


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H 2O 2 vapor izer

1 Ster i le ai r

2 Liquid H 2O 2

3 Ga seous H 2O 2

4 Retractable r insing tube

5 Electr ic heate r

6 Tempe rature control

7 Purging-tube l i f t ing

mechanism

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A Revolution! Plastic Bottle Steri l ization Entirely Without Water

Take Advantag e of the Cutt ing Edge ofKHS Alfill Technolo gy

Hydrogen peroxide (H2O2) and w arm air are used

for steril ization. A proven method t hat has been used in

cardboard box processing for decades.

KHS Alf i l l now enables you to take advantag e of

this safe and successful method for processing

plastic conta iners.

The KHS Alfi l l dry steril ization metho d involves heating a

mixture comprised of an H2O2 concentrate and sterile

air by m eans of a vaporizer. The result ing gaseous mixture

is applied to th e interiors and exteriors of the containers.

The difference in temperature causes the gas to condense

on the container walls.

All surfaces are moistened.

Flawlessly.

During the course of processing, w arm air activates the

steril ization process and eliminat es any moisture remaining

on t he container w alls. All surfaces are thus sterile and dry.

This me thod re quires less energy. You save on the

cost o f w at er, w at er t r ea t ment , and w ast ew at er in

addit ion to steri lant.

You can process all bottle styles regardless of the shape

and size. Even undercuts and dif f icult t o access hollow

spaces such as the handle areas of plastic decanters are

reliably treated and steril ized.

Great f lexibil i ty and creativity in the de sign of your

unique containers styles.


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Greater Freedom for N ew Produ ct Ideas

The N ew KHS Alf i ll ACF Generation w ith H 2O2 Sterilization

Special features that set new standards in aseptic

cold filling:

Compact isolator t echnology for steril izer, activator,

and fi l l ing valve areas.

M inimal steri le areas a KHS Alf i l l patent.

Saves t ime and effort .

Can be used for all styles of plastic bott le, regardless

of shape and size.

Full microbiological safety coupled with compelling

economy.

Drastic reduction in sterilization operating costs in

comparison to conventional method s.

M odular design system. Optionally high-performance

linear or rot ary f i l lers.

Great f lexibil i ty. The r ight solution for all capacity

ranges.

Product and container changeover without format part

changing. Stainless steel infeed disk. No plastic feedscrews.

M aximum machine f lexibil i ty and readiness for use.

Hygienic design roof-l ike machine tables and f orced

runoffs. No corners, recesses, or niches.

Highest standard of hygiene as prerequisite fo r

aseptic cold filling.


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Air control in the a septic block

Innovative air management . The air is steril ized highly

pure, class-100-compli ant in special HEPA fi lt ers* ,

then forced through a patented system of baffle plates in

separate air f i l ter circuits tow ards the bott le infeed and

discharge, from w here it is specif ically disposed of throu gh

an exhaust pipe system.

Advantages: Assured controllable air process for

a steri le air atm osphere; minimum cost of steri le air

and high process hygiene.

* HEPA fi l ter = high efficiency particulate air f i l ter


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The Heart of KHS Al fil l ACF Techno log y

Innosept , the M odular Concept System

Dry bottle steril ization inside and out, dry closure

steril ization all with the H2O2 method.

Safe complete packaging steri l ization.

Patented m ini- isolator technology (m ini sterile chamber)

filling process.

Perfect sterilization of bottles and closures.

Neck handling maintains continuous bottle f lows.

Free choice of bottle sizes and shapes.

Great freedom of bott le design.

Completely steril izable f i l l ing system with cutting-edge

fil l ing t echnology.

Microbiological safety down to the very last detail .


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Complete stainless steel design.

Long service life.

Integ rated CIP/SIP systems.

Biological safety for all l ine components

and p roduction paths.

Continuous process data acquisit ion and complete

recording of all parameters.

Complete control and documentation of the

entire filling process.

Modular system concept.

Flexibil i ty in l ine planning, optimum uti l ization

of existing space.

Layout opt ions (modular system )

U-shaped layout L-shaped layout I -shaped layout

Auto matic sanit izing and disinfection of all surfaces

in t he sterile zone. 360-degree spray nozzles.

Perfect process hygiene.

Air f lows directed away from crit ical towards

non-critical areas.

Safety also at t he transit ion points betw een

steri le zones and the surrounding area.

Innovative sterile air lock system w ith barrier effect

in the ent ry and exit zones.

Controlled steri le air management.

All drives and controls are located outside the

sterile zone.

Unlimited access during production.


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Optional: Combined fi l l ing system for bott l ing carbonated (left)

and non-carbonated be verages (right).

Advanced electronic volumetric filling systems from KHS

have been in operation successfully worldwide for many

years. All prerequisites for aseptic filling are met.

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Precision Dow n to the Last Bottle

For Carbonat ed and No n-carbonat ed Beverages

The computer-controlled volumetric f i l l ing method

ensures exact f i l l ing volumes.

Product savings.

Absolute non-contact f i l l ing of non-carbonated beverages.

No built- in parts, no valve components extending into

bottles.

Best prerequisites for aseptic filling.

Combined fi l l ing of carbonated and non-carbonated

beverages (option).

Flexibility in the range of applications.

Computer-controlled f i l l ing process.

Continuously documented optimum fi l l ing

parameters.

Hygiene-complian t valve design. Functions activated

by aseptic mem branes. No guides and springs in the

product area.

Easy to service. Optim um CIP/SIP condit ions.

Fully automatic CIP/SIP capabilities.

Preprogramm ed sanit izing and disinfection m easures.


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By-weight bo tt l ing system in the m ini - isolator .

1 Fil l ing valve

2 Weighing cel l

3 Mini - isolator

Gett ing int o t he Thick of I t

By-w eight Do sing Filling Syste m

For all prod ucts of varying consistency.

From low viscosity to pasty.

Products such as:

M ix ed m il k dri nk s

Pulp y beve ra ges

Pro duct s cont ain in g cere als or pi eces of f ru it

Yog ur t drink s

and m any m ore

Weighing system

High f illing accuracy.

Ideal for weight contents that need to be

specif ied on t he packaging

Computer-controlled, self-regulating f i l l in g process.

Exact filling. Product savings.

Non-contact f i l l ing

High hygienic safety.

Bottl ing system f or all shapes and types of plastic bott le.

No format changing if bott le mouths are the same.

Flexibility of system utilization

Neck handl ing f rom the bot t le infeed to the bot t le

discharge.

Gentle container control.

Optional :

Bottling of several products simultaneously.


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Linear fi l l ing block

1 Bot t l e i n feed

2 Ster i l izer

3 Activator

4 HEPA fi l ter

5 Fi ll ing valves

6 Capper

7 Air lock

8 Ster i le ai r control

All-in-One Solution

Innosept LINEFILL The Compact Linear Filler Solution atup to 6,000 Bott les/h

Linear f i l l ing concept for plastic bot tles.

For all bottle shapes and sizes.

Capacity range of up to 6,000 bottles/h.

Great f lexibil i ty coupled with highly economical

operation and added benefits.

Non-contact f i l l i ng of n on-carbonated beverages.

Fil l ing system free of m oving p arts and fi l l ing tubes.

Fewer wear parts.

Less serv icing.

High aseptic safety.


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Aut omati c CIP program for steril izer and fi l ler

M aximum hygiene safety

Push-of-a-butt on product changeover.

Time savings and flexibility.

Smooth surfaces free of niches and corners.

Fulf i l ls maximum hygiene dem ands.

For ESL and A CF filling .

Optimum adaptation to your product

requirements.

Optional :

Bottling of several products simultaneously.

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M ini- isolator technology f or bot tle steril izer and f i l ler/sealer.

M inimal steri le zone for t he entire process.

H2O2 process of dry bott le and closure steril ization.

With all of t he advanta ges of a rotary f i l ler.

Compact machine design.

Space savings.

Neck handling from infeed to discharge.

Gentle bot t le conveying.


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Innosept closure steri l ization.

1 H 2O 2 vapor izer head

2 Liquid H 2O 2

3 Ster i le ai r

4 Ga seous H2O 2

5 Ster i l izat ion drum

6 Ster i le a i r cap cool ing

7 Hot ai r dr ier

8 Fresh ai r b lowe r

9 HEPA fi l ter

10 Exhaust b lower

11 Exhaust ai r

Sterile at a Low Price

Perfe ct Screw -cap Ste rilizat ion

Patented KHS Alfi l l method of hydrogen peroxide (H2O2)

steril ization. All surfaces covered entirely w ith condensate.

Regardless of cap shapes and materials.

Reliable steri l ization of the entire cap.

Dry sterilization process.

Drastic costs savings.

No w ater, less energy consumption.

High output

Up to 50,000 caps/h for 28-mm or 38 -mm

cap diame ters.

Adaptation capabilities to all line sizes.

Reliable process withou t af fecting cap prop erties.

No lubricant washout.


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Can be integrated in to t he bott l ing l ine CIP/SIP sanit izing

intervals.

M aximum hygienic safety.

Small, compact design. M ade entirely of stainless steel.

Fits in all bott l ing lines. Can be integrated be tw een

the sorter and t he capper.

Also suitable for ret rofit in existing l ines, even t hose

from ot her manufa cturers.

Closure ster i l izer instal led on a separate base frame Closure ster i l izer integrated into an ACF f i l l ing block

Non-contour and non-shape-dependent.

Dimensional stabil ity and exact f it of caps unaffected

even during machine standstil l .

For all one-piece and composite closures and sports caps.

Wide range of app lications, great f lexibil i ty.

Efficient air management.

Extraction of H 2O2 vapors.

Low steri le a ir consumption.


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Entirely different m ode of operation versus conventional

cappers.

Station ary capping spindle. No vertical mot ion.

High stabil ity. Litt le we ar. Low -cost operation and

maintenance.

Slender center column w ith addi t ional no zzles for inside

cleaning behind t he capping spindles.

Highest- level hygiene safety.

Caps are transferred from t he cap chute to t he capping

head by a transfer star and ramp.

Reliable, fast mode of operat ion.

On top the central computer.

The electronic equipment is located outside the

isolator zone.

Bott le posi t ioning by a l i f t ing cam, l i f t ing rod with a

spring, and bot t le neck p lat form.

Gentle, short-stroke bott le motions.

Innofill SV Aseptic Screw Capper

The Mister Clean of Cappers

Layout of the Innofi l l SV screw capper

1 Control

2 Servo dr ive

3 Open bear ing

4 Capping head

5 Bott le l i f t m echanism

6 Ster i le zone


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Constructed in KHS Hygiene Design

No Lubricat ion in the Sensit ive Bottle M outh Area

Open-type design of all components. Capping elements

w ith f lushing openings and exposed clamping collars. Pins

instead of locking b alls to hold caps in place.

Reliable, autom atic exterior sanit izing and disinfection.

M icrobiological safety

Fast changeover to other screw cap styles and diameters.

High m achine availabil ity.

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Capping head

1 Flushing opening

2 Exposed clamping col lar

Speed and t orque curve dur ing the capping process

1 Speed

2 Capping distance

3 Torque

4 Speed curve

5 Torque curve

6 Capping torque t olerance range of conventional screw cappers

7 Capping torque tolerance range of the KHS Innofi l l SV screw capper


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Water Wat er Syrup

Water deaerat ing Sterile f ilt rat ion of w ater Syrup past eurizing Blending Carbonat ing Buffer tank Filling

Deaerating vessel

Steri le fi l ter

Steam

Heater

Heatretention

Heat exchanger

Buffer tank

CO2

Carbonatingand steri lebuffer tank

Filler

Finishedbeverage

Innopro ASEPTOMIX Blender

* UHT = U l t r a -h igh temper atu r e

* * FP = Flash pasteur iz ing

From the Raw Product t o t he Capped Bott le

Comp let e ACF Technolog y

Layout of process engineering according to customer and

product-specif ic requirement s.

Flexibility of system utilization

Sugar management, syrup room, deaerat ing, b lending,

UHT* /FP** , ster i le buf fer tank a l l f rom KHS.

Perfect orientation of all process modules to ACF

requirements.

Aseptic valve and sensory equipment m atched to

the process.

CIP/SIP capa bilitie s, product assurance.

Thermal beverage treatment

Reliable product pa steurization.

Use of sterile buffer t anks.

Continuous availability of sufficient quantities

of product and thus a constant supply to the filler.

Integra ted CIP/SIP systems.

Basis for a high standard of hygiene.


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M icrobiological Safety

CIP/SIP Technolo gy w ith Sanit izingand Disinfection Cycles

Integrated CIP/SIP functionality.

Safety for all l ine comp onents and production

paths.

Auto matic sanit izing and disinfection of all surfaces

in the m ini- isolator.

Prerequisite for consistent sanitizing and

disinfection results.

Short interim disinfection carried out automatically

at defined intervals; main sanit izing for each product

changeover or at prespecif ied int ervals.

Safety has priority.


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Validation Acceptance Support

KHS Is and Rem ains Your Part ner

Training in system hygiene and aseptics for

m ach in e op era tor s a nd m ai nt en an ce pe rso nn el

qu al it y assu ra nce an d pl an t in spe ct io n

kn ow le dg e t ra nsf er.

ACF handbook on proper conduct in the area of and

operation o f aseptic systems oriented to customer-specif ic

condit ions.

Always up-to-date on the state of the art of ACF

technology.

M obile laboratory facil it ies available.

Preparation o f sampling plans and assistance in t he

preparation of HACCP* concepts in the product area.

Validation and spray shadow tests, sample-taking at

all machine components repeated sampling and

examination of f i l l ing results.

Extensive microbiological inspections.

Preparation and execution of microbiological validation and

acceptance.

Advice regarding m icrobiological and hygiene issues and

consult ing on t he layout and operation of aseptic systems.

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* HACCP = Hazard analysis and cr i t ical control points


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Clear, simple operator prompting.

User-fr iendly. Clearly arranged. Perfect information

on current system statuses.

Fast communication with permanent feedback between

machine operator, contro l , and system.

Reliable l ine operating.

Immediate reaction to deviations in target data,

assured adherence to all beverage-a septic

parameters.

Online monit oring of crit ical control points (CCP).

Consistent control, systemat ic and permanent monitoring

of all beverage-aseptic process parameters.

Comprehensive information on completed and

on-going processes. M aximum safety during

sanit izing, steri l izing, and production.

AIS system t o record disruption d ata, production statistics,

log aseptic data, and document process flows.

Continuous transparency of beverage-specific product

quality and line efficiency.

AIS KHS Plant Inform atio n System

A M ust for Asept ic Fill ing


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K H S M a s ch i n e n - u n d

A n l a g e n b a u A k t i e n g e se l l sc h a f t

J u c h o s t r a s s e 2 0

D -4 4 1 4 3 D o r t m u n d , G er m a n y

Te l . + 4 9 ( 2 3 1 ) 5 6 9 - 0

Fa x + 4 9 ( 2 3 1 ) 5 6 9 -1 5 4 1

P l a n i g e r S t r a s se 1 3 9 - 1 4 7

D - 5 5 5 4 3 B a d K r eu z n ac h , G e rm a n y

Te l . + 4 9 ( 6 7 1 ) 8 5 2 - 0

Fa x + 4 9 ( 6 7 1 ) 8 5 2 -2 4 1 1

w w w . k h s - a g . c o m

Em a i l : k h s@ k h s- a g .c o m

K H S M a s ch i n e n - u n d

A n l a g e n b a u A k t i e n g e se l l sc h a f t

W e r k K H S A l f i l l

R u w o l d t w e g 1 4

D - 2 2 3 0 0 H a m b u r g , G e rm a n y

Te l . + 4 9 ( 4 0 ) 6 3 7 0 3 - 3 6 1 2 1

Fa x + 4 9 ( 4 0 ) 6 3 7 0 3 - 3 6 1 5 0

Em a i l : k h s - a l f i l l@ h h . k h s- a g .c o m

30-1992-01-2

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1143_acf - dry sterilization

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