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FILLING MACHINES FOR DUAL COMPARTMENTSYSTEMS (BAG ON VALVES)
MACHINERY DIVISION
CO
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General features of Coster Bag-On-Valve filling machines
Coster Tecnologie Special i , founded in the
early 60’s, serves as a global partner in
the aerosol sector, offer ing aerosol com-
ponents and machines for f i l l ing aerosol,
spray and dispensing products.
Leveraging over 40 years experience and
know-how of both i ts valve and machinery
divisions, Coster is a world leader in the
provision of innovative services and high
qual i ty products designed to meet custom-
ers’ needs.
To sat isfy the increasing demand for Bag-
On-Valve f i l l ing, Coster has developed a
series of machines to al low for a secure
processing of dual compartment systems,
ranging from semi-automatic ( for labora-
tory and small-scale production) to ful ly
automatic machines, suitable for both l iq-
uid and compressed gas (Nitrogen, Air) .
The range of Coster BOV f i l l ing machines
is complemented by a series of anci l lary
machines such as mixing units for the pre-
parat ion of post-foaming gel, which al low
Coster to offer complete support to cus-
tomers for al l BOV f i l l ing requirements.
Coster BOV f i l l ing machines are currently
used to f i l l shaving gels, pharmaceutical
products, cosmetics and food.
BOV filling machine with a production speed up to 50 CPM for a customized product. The machine carries out the following operations: undercup pressurisation and internal crimping, external crimping, through the valve pressurisation with LPG, vacuum purging, product filling in the bag, check of filling pressure.
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Coster Bag-On-Valve filling machines are suitable both for liquid and compressed gas
The key feature of BOVs is the fact that
they keep the product separate from the
propel lant: the propel lant, l iquefied or
compressed gas, is contained inside the
can outside the bag and the product is
contained inside the bag. Coster BOV f i l l-
ing machines al low f i l l ing of a wide range
of products and both types of propel lants.
As shown in the pictures below, the fil l ing
cycle begins with the insertion of the BOV
into the can and proceeds in slightly differ-
ent ways depending on the propellant used.
For l iquefied gas, the f i l l ing cycle goes on
with valve crimping, through the valve pres -
surisat ion with l iquefied gas, vacuum purg-
ing and through the valve product f i l l ing.
For compressed gas, the cycle goes on
with undercup pressurisat ion with com-
pressed gas and valve crimping, vacuum
purging and through the valve product f i l l-
ing. I t is advisable to use a pressure check
stat ion after undercup pressurisat ion in
order to check the f i l l ing pressure of com-
pressed gas.
The f i l l ing cycle of Bag-On-Valves then
proceeds as in the standard aerosol cycle
(check weight, water bath, actuator and
overcap f i t t ing).
THROUGH THE VALVE PRESSURIZATION AND FILLING
1st STAGE Insertion of Bag-On-Valve
into the can
2nd STAGE Crimping of the valve
onto the can
PRODUCT
5th STAGE Through the valve product
filling in the bag
UNDERCUP PRESSURIZATION, THROUGH THE VALVE FILLING
1st STAGE Insertion of Bag-On-Valve
into the can
COMPRESSED PROPELLANT:
AIR – N2
2nd STAGE Undercup pressurization and
crimping of the valve onto the can
4rd STAGE Removal from the valve stem
of any residual propellant
PRODUCT
5th STAGE Through the valve product
filling in the bag
3rd STAGE Can pressurization through
the valve with liquefied propellant
LIQUEFIED PROPELLANT
4th STAGE Removal from the valve stem
of any residual propellant
3th STAGE Pressure
check
BO
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CY
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BOV filling cycle
As seen in the previous pages, the BOV f i l l ing cycle begins with BOV insert ion and
proceeds in sl ight ly dif ferent ways depending on the propel lant used.
Above: automatic indexing unit with a production speed up to 40 cans per minute for filling the BOV with post-foaming shaving gel, with liquefied and/or compressed propellant. The unit is equipped with Coster Mix, an external automatic mixing unit for production of post-foaming gel. The filling cycle is completed by actuator and overcap insertion.
FOR BOTH PRESSURIZATION AND FILLING SYSTEMS
Above and below: AB175 BOV sorter, complete with special elevator for soft filling, reverse roller conveyors, shot device for BOV insertion over cans, sensors for presence of valves on conveyor. This sorter enables production of up to 60 CPM.The shot system is provided with a scroll to select one valve at a time and a spout to thrust it into the pipe for the shot.
1 - Insertion of Bag-On-Valve
into the can. To ensure a safe
automatic handl ing and inser-
t ion of BOVs, Coster has de-
veloped the AB175 BOV sorter
(below, left ) . Immediately after
the BOV insert ion, the machine
checks the proper insert ion of
the BOV into the can (r ight).
BO
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CY
CLE
2 - Undercup pressurisation and valve
crimping. The
c o m p r e s s e d
gas is filled in-
side the can
outside the bag
and then the
valve is crimped
onto the can.
THROUGH THE VALVE PRESSURIZATION AND PRODUCT FILLING
UNDERCUP PRESSURIZATION, THROUGH THE VALVE PRODUCT FILLING
2 - Valve crimping onto the can. The crimping
head enables
precision to 0.05
mm in crimping
dimensions and
is equipped with
a crimping jaw
that enables 3
mil l ion cycles.
3 - Through the valve pressurisation. The
liquefied propellant is filled through the valve
inside the can
outside the bag
by means of in-
ternally polish-
ed s ta in less
steel high-ac-
curacy pneu-
matic meter-
ing cyl inders.
3 - Pressure check. Optional step to ver-
i fy the value of compressed gas pressure
inside the can.
Left: schematic view of an automatic indexing unit with a production speed up to 40 cans per minute for filling BOVs with pharmaceutical product and compressed gas. The unit is equipped with a diaphragm pump for supplying the product to product filling stations and is placed under a laminar air flow. The filling cycle is completed by actuator and overcap insertion.
BO
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CY
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Above, Coster Mix is an automatic unit for the production of post-foaming gels (close-ups top and below). Coster Mix is available with a static or dynamic mixer. The unit must be connected to the BOV filling machine.
4 - Release. Stat ion for the removal from
the Bag-On-Valve stem of any residual
propel lant re-
maining due to
the f i l l ing of
the propel lant
th rough the
stem itself.
FOR BOTH PRESSURIZATION AND FILLING SYSTEMS
5 - Through the valve product fi l l ing. The
product is f i l led thro ugh the valve inside
the can into the bag by means of inter-
nal ly pol ished stainless steel high-accu-
racy pneuma-
t i c mete r ing
cyl inders. The
p roduc t f i l l -
ing stat ion re-
quires a prod-
uct supply sys-
tem such as
pumps for l iq-
uids or machines l ike Co ster Mix (r ight) for
the produc t ion of post-foaming gels.
6 - Valve stem cleaning. Optional sta-
t ion for the removal from the valve stem
of any res idua l product remain ing due
to the f i l l i ng
of the product
th rough the
s tem i tse l f .
SE
MIA
UTO
MA
TIC
UN
ITS
AN
D T
OO
LS
Semiautomatic units and tools complete Coster’s range of BOV filling machines
Above: semiautomatic unit for undercup pressurisation and crimping of valve. The unit is suitable for laboratory or low-speed production lines.On the right, close-ups of the undercup pressurisation and crimping head.
Top, Coster Mix-3 is a laboratory device suitable for mixing two or more products which create an emulsion by means of agitation: for example for mixing gels with isopentane to obtain post-foaming gel. Above, close-up of Coster Test Tube (left) and product feed hopper (right).
Coster’s BOV fi l l ing machine range includes
semiautomatic units suitable for laborato-
ry tests and/or low production speed l ines
and optional tools useful for safe BOV pro-
duction.
Coster semiautomatic units products in-
cludes machines for:
- Standard valve crimping
- Through the valve pressurisat ion
- Undercup pressurisation and valve crimping
- Into the bag product f i l l ing.
In addit ion to machines, Coster offers a
series of BOV f i l l ing tools, including:
- Devices for the production of post-foam-
ing gels, avai lable in a lab version, Mix-3,
and in a production version, Coster Mix
- Coster test tube, a device suitable for
optical checking of product behaviour af-
ter f i l l ing
- AB-175 system for safe automatic inser-
t ion of the BOV into the can: sorter com-
plete with special elevator for soft f i l l-
ing, reverse rol ler conveyors, shot device
for BOV insert ion into the can, sensors for
presence of valves on conveyor. This sys-
tem is suitable for up to 60 CPM.
HEAD OFFICESCoster Tecnologie Speciali S.p.A.sales@coster.com
Via Leonardo da Vinci, 2 20016 Pero (Milano), Italy
TEL: +39 02636161FAX: +39 0229006706
MACHINERY DIVISIONCoster Tecnologie Speciali S.p.A.info.machine@coster.com
Via Leonardo da Vinci, 4 20016 Pero (Milano), Italy
TEL: +39 02339561FAX: +39 0233956372
FRANCE,MAGHREB
Coster s.à.r.l. sales.fr@coster.com
ZI Mitry Compans Rue Gay Lussac77290 Mitry Mory
TEL: +33 (1) 6467 9655FAX: +33 (1) 6467 0404
INDIA Coster India Packaging Pvt. Ltd.info@costerindia.com
C-021-A, 2nd floor, Super Mart Commercial Complex-1DLF Phase IV - Gurgaon-122016 Haryana
TEL: +91 (124) 404 3701FAX: +91 (124) 404 3704
LATIN AMERICA Coster Packaging S.A.ventas.ar@coster.com
TEL: +54 (0230) 4466 206FAX: +54 (0230) 4496 664
MALAYSIA Costerpack Manufacturing Sdn. Bhd.costerap-karen@costerpackmfg.com.my
TEL: +60 (7) 354 1122 FAX: +60 (7) 354 4898
SINGAPORE Coster (Asia Pacific) Pte. Ltd.sales.sg@coster.com
TEL: +65 65497031 FAX: +65 65497001
SPAIN, PORTUGAL Costertec, S.A.sales.sp@coster.com
TEL: +34 (93) 859 1038FAX: +34 (93) 859 3510
UNITED KINGDOM Coster Aerosols Limitedsales.uk@coster.com
TEL: +44 (1438) 367 763FAX: +44 (1438) 728 305
U.S.A. Coster USA Inc.sales@costerusa.com
TEL: +1 (847) 760 6040FAX: +1 (847) 760 6035
BRASIL Packaging do BRASILvendas.br@coster.com
Ruta 8, Km 60 - Calle 14 y 9B1629MXA Parque Ind. Pilar - Buenos Aires 5, Jalan Firma 3 Kawasan Perindustrian Tebrau IV - 81100 Johor Bahru, Johor3 Temasek Avenue - Level 34 Centennial Tower Singapore 039190 Besalú, 408570 Torelló - BarcelonaLindrick Way, Barlborough – Derbyshire S43 4XE – UK1625 Shanahan Drive, South Elgin Illinois 60177 USARua Gomes de Carvalho, 1069 – ANDAR: 3 CEP 04547-004 – São Paulo SP – BRASIL
TEL: +55 11 34884600TEL: +55 19 981008783
TURKEY Aerosol Valf Sanayi A.S.info.avs@fareva.com
Geposb-Gebze Plastikçiler Organize SanayiBölgesi Inönü mahallesi 7, Cadde Gebze/Kocaeli
TEL: +90 (262) 751 2713FAX: +90 (262) 751 2180
EGYPT, YEMEN, GCC Cesam Engineering & Trading Co.cesam@cesam-eg.com
I.Z. # 2, Str. # 81 btw. Rd # 18 & Rd # 20POB 153 October VI City - Giza 12573 Egypt
TEL: +20 (2) 3833 9896FAX: +20 (2) 3833 5197
GREECE, CYPRUS Paneuropean S.A.admin@pispinis.gr
N. 17, Souri street121 31 Peristeri Athens N. 17, Souri street
TEL: +30 (210) 574 141417FAX: +30 (210) 574 1418
GUATEMALA Representaciones del Caribe S.A. repca@repca.com
14 Avenida 7-12 Zona 14 Bodega # 8Guatemala C.A. 01014
TEL: +502 24 210 300FAX: +502 24 210 301
HUNGARY Unlimited Business Ltd.csatari.olga@gmail.com
Utas utca 91025 - Budapest
TEL: +36 204 142 562
ISRAEL Maydan Representatives Ltd.mayrep@bezeqint.net
Kehilat Saloniki str. 1369513 Tel Aviv
TEL: +972 (3) 540 3710FAX: +972 (3) 549 2524
JAPAN Koike Chemical Co. Ltd.t.hosokawa@kck.co.jp
3-2-1, Kinshi, Sumida-KuTokyo 130-0013
TEL: +81 (3) 5610 5169FAX: +81 (3) 5610 5171
LEBANON Zakka Multitec SARL.sales@zakkamultitec.com
P.O. Box 90360Jdeidet El-Maten
TEL: +961 (1) 870 942FAX: +961 (1) 895 654
ROMANIA, BULGARIA, MOLDOVA
Professional Valves Supplier S.r.l.radu.vartejaru@valves.ro
North Riding, 27 Montagu, 137 Pritchard Street2194, Randburg
TEL: +961 1 890654FAX: +961 1 895654
SOUTH AFRICA CostPac SAandrea@costpac.co.za
27 Montagu, 137 Pritchard StreetNorth Riding, Randburg - 2169 RSA
TEL: +27 82 393 0864SKYPE: andrea.protti1
TURKEY Metpak Temsilcilik Diş Ticaret Ltd. Ştiinfo@metpak.com.tr
Barbaros Mah. Apaydın Sok. No. 2 D. 3-434746 Ataşehir - Istanbul
TEL: +90 216 411 87 87FAX: +90 216 478 53 53
BALTIC COUNTRIES, RUSSIA, C.I.S.
VA Intertrading AGmarina.smirnskaya@gmail.com
Kantemirovskaya Street 58Office 7038 Moscow 114577
TEL: +7 (495) 651 9335
BANGLADESH (MACHINERY)
Precisa Techno Tradeprecisa@precisabd.com
Road 27, House 39, Sector 7Uttara, Dhaka - 1230
TEL: +880 (2) 89 31 056FAX: +880 (2) 89 31 139
BULGARIA Inova Plus Ltd.inovaplus@abv.bg
1 Andrey Lyapchev Blvd.1756 Sofia
TEL: +359 888 739782FAX: +359 888 739782
CHINA, TAIWAN, KOREA Anomatic (Suzhou) Metal Packaging Co. Ltd.pjm@anomatic.com
1999, LinHu Avenue, Fenhu Economic Development Zone- Wujiang, Jiangsu Province 215211, China
TEL: +86 (512) 6326 9696FAX: +86 (512) 6301 6756
IRAN (MACHINERY)
Padine Co. Ltd.info@foumanchimie.com
No. 53, Rasht Street, Hafez Ave.Tehran, Iran - 1591818971
TEL: +98 (21) 8873 8833FAX: +98 (21) 8873 7686
TURKEY Metpak Temsilcilik Diş Ticaret Ltd. Ştiinfo@metpak.com.tr
Barbaros Mah. Apaydın Sok. No. 2 D. 3-434746 Ataşehir - Istanbul
TEL: +90 216 411 87 87FAX: +90 216 478 53 53
BANGLADESH (PACKAGING COMPONENTS)
Orbit Corporationrokun@orbitcorpbd.com
“The Emporium Building” · House# 14/1, Level - 13 (C -13); Shamoli, Dhaka - 1207
TEL: +880 (2) 81 58 805FAX: +880 (2) 81 59 957
GERMANY, AUSTRIA,
SWITZERLAND, POLAND, CZECH REPUBLIC
Coster Tecnologie Speciali GmbHsales.de@coster.com
Siemensstraße 2276275 Ettlingen
TEL: +49 (7243) 5483-0FAX: +49 (7243) 5483-54
COMPANY / EMAILAREA ADDRESS PHONE / FAX
COSTER GROUP SALES ORGANIZATION
IRAN Padine Co. Ltd.info@foumanchimie.com
No. 53, Rasht Street, Hafez Ave.Tehran, Iran - 1591818971
TEL: +98 (21) 8873 8833FAX: +98 (21) 8873 7686
CANADA Norlimar Canada Inc.sales.nl@coster.com
225, Chemin SinclairBrownsburg-Chatham Québec J8G 1W7
TEL: +1 (514) 696 2947
ALGERIA, EGYPT, JORDAN, SYRIA, YEMEN, GCC
Gulf - Alfourat FZCahmad@gulf-alfourat.com
P.O.Box: 16670RAK-UAE
TEL: +971 720 426 68FAX: +971 15 660 3267
BENELUX,SCANDINAVIA
Coster Benelux & Scandinavia B.V.sales.nl@coster.com
Pascalweg 3, Industrieterrein Marslanden D8013 RC - Zwolle, Netherlands
TEL: +31 (38) 4652 080FAX: +31 (38) 4657 076
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