krones Product Treatment SystemsSafety for Every Product

krones agSteinecker PlantRaiffeisenstr. 3085356 FreisingGermanyInfoline: +49 (+ 81 61) 953-0Infofax: +49 (+ 81 61) 953-150Internet: www.krones.com

Process Technology

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krones Systems for Product Treatment

Advantages:

Modular design for flexibility andindividuality Optimally gentle product treat-mentLong service lives High efficiencyCoherent cleaning concepts Short bottle-to-bottle times High plant availability Uniform components Uniform “touch-and-feel” systemOne contactOne overall responsibilityOptimal control conceptsNo interface problems

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VarioFlash/VarioAsept–Top Safety and Quality

The thermal treatment of a productis a crucial process step between itsproduction and its filling. Only if thetechnology is optimally designed forthe task to be performed, top qualitycan be achieved even for supersensi-tive food. Choosing the right heatexchanger, the right heating temper-ature and a synchronized heat main-tenance time is instrumental in bring-ing about the required shelf-live with-out the risk of significant changes inthe product’s sensory characteristics.

krones Systems for ProductTreatment

VarioFlash

Through the VarioFlash, the procedural processing know-howis combined with the approvedkrones competence in fillingtechnology.

VarioAsept

Highest sanitary standards arerealised for the aseptic processunder this model range, the com-ponents being specifically alignedto the requirements. With theplants for flash pasteurization,krones is able to compile a spe-cific and individual package forevery product and every task.

The highly flexible concept offerscustomized applications for - beer- carbonized soft drinks - fruit and vegetable juices with

and without pulp - milk and dairy products - hot filling of fruit juices - energy drinks

Modular Design

The modular design provides a multi-tude of options and modules so thata plant will be delivered which trulyfits the application.

Modules

Buffer tank - With or without agitator- Various product gasses- Sterilisable by hot water or steam

Utility module

- Product inlet or outlet- CIP connection- All utility media (gasses, steam,

water)

Degassing module

- Degassing up to 0,5 mg/l O2

Homogeniser

Coordinated with the products

Heat exchanger unit

- Highly cost-efficient due to high energy recovery

- Plate heat exchanger - Shell and tube heat exchanger for

pulpous and viscous products

Heat maintenance sections

- Switchable, depending on prod-uct also automatic

- Different materials depending onproduct (1.4404 – titan)

Capacity

Up to 60.000 l/h

Control

- Visualisation via Botec using the Scada system Zenon

- Operated by on-site touch panel - Fully automated flow of cleaning

and production programs - Interface-free automation

concept, consistent throughoutthe plant

- Storage of key data for batch tracing

krones VarioFlash / VarioAseptSystems:

- Modular design for flexibility andindividuality

- Individually designed heatexchangers and heat mainte-nance sections

- Buffer tank and plant may be cleaned and sterilised separately

- Selection of the ideal heatexchanger (plate, easy flow plate,multitube or monotube)

- Optimally gentle product treat-ment

- Long service lives - Highly efficient due to energy

recovery and small discharge quantities

- Coherent cleaning concepts - High plant availability - Optimal control concepts

krones VarioFlash / VarioAseptSystems in Conjunction withkrones Filling Systems:

- Uniform components - Uniform “touch-and-feel” system- One contact- One overall responsibility

VarioFlash B for beer with plate heatexchanger

VarioAsept J forpulpous juices withshell and tube heatexchanger

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krones has decided to include thekey competences, decisive for thesuccess of an aseptic project, in theirportfolio. This involves the sterilewater UHT called AquaAsept.

Sterile Water Consumers

In the field of aseptic filling, sterile water is needed at different points and for different tasks:- Rinser: rinsing the containers to

be filled - Hygienic centre: foam cleaning

and subsequent flushing of the isolator

- Cap bath: disinfecting the closures- Filler: sterilising at up to 135 °C

Module

- UHT module for water treatment- Variable connection to steam or

hot water system - CIP module with various specifi-

cations

krones AquaAsept Systems:

- Modular design - Variable heat maintenance

sections at different heat main-tenance temperatures

- Highly efficient due to energy recovery and small discharge quantities

- Coherent cleaning concepts - High plant availability - Optimal control concepts

AquaAsept–Sterile WaterUHT

krones AquaAsept Systems inConjunction with krones FillingSystems:

- Uniform components - Uniform “touch and feel”- One contact person- One overall responsibility

Plant dataContinuous output 10 m3/hFlushing capacity 25 m3/hDimensions in mm (l x b x h) 4500 x 2255 x 3630CIP module - dimensions in mm (l x b x h) 1850 x 1450 x 3630

AquaAsept

View of anAquaAsept with CIP module

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The CIP plants VarioClean serve toimplement coherent cleaning conceptsbeing an essential issue in the trouble-free and microbiologically unobjection-able operation of a line.

So, the idea “everything from a singlesource” is realised consistently so thatoptimal cleaning results are provided.Be it manual or fully automatic, thecleaning concept is perfectly adjustedto the plant component to be cleaned.This means, filler, rinser, mixer, flashpasteuriser, lines and also the tanks areunfailingly cleaned.

Here too, the advantages of the modu-lar design have been opted for. Thecapacities of the different installationsizes cover all tasks arising in bottlecellar, syrup room or dairy. Dependingon the cleaning agent, the number of tanks can be flexibly varied, therequired tank sizes and CIP lines aresubject to the plant size and thenumber of single units to be cleaned.

Modular Design

- Tanks- 6 different tank sizes per appli-

cation and cleaning agent:1,5 m3, 3 m3, 5 m3, 8m3,10m3, 12 m3

- Tanks for hot agents will be insulated

- Different cleaning agents- Recovered water- Caustic- Acid- Hot water- Disinfection solution- Fresh water

Base Frame

- Pumps, heat exchanger and control cabinet are mounted on a base frame

- VarioClean systems are manufac-tured and tested mechanically andelectrically in our workshop

- The systems will just be set-up andcommissioned on site.

Classes

- Different prerun sizes are availablealigned to the product capacities of the krones filling and process systems VarioClean 15, VarioClean 30,VarioClean 45, VarioClean 60

Dosing the Concentrates

- From concentrate cask with suction tube

- Directly from the central chemicalsstore

- From the central chemicals store over daily storage tanks

Prerun Lines

- Up to 5 different cleaning preruns are feasible depending on the number of plants to be cleaned in parallel

Integrating the VarioClean

- Double seat valve matrixes for fully automated concepts

- Manual panel with swivel bends

Manual CIP Concepts

- Every step is started and monitored bythe operator

- Ideal for cleaning manual filters and mixers

- Clearly arranged operating elements guarantee simple and safe operation

Fully Automated CIP Concepts

- Absolutely necessary to clean fillers,mixers and flash pasteuriser plants being also equipped with a control

- Utmost ease of use - Top safety as the cleaning parameters

temperature, flow, time and conduc-tance are continuously monitored

- Permanent nominal value/actual value comparison and automatic adjustment

Control

- PLC control for fully automated operation

- Visualisation via Botec using the Scada system Zenon

- Operated by an on-site touch panel - Fully automated flow of the cleaning

programs - Interface for production data

acquisition

VarioClean–Optimal Cleaning of Process Unit and Filling

The core of the fully automated oper-ation is the sophisticated controlwhich is based on the technically ma-ture process control system Botec.The control has been tailored specifi-cally to the requirements of practicalapplications.

The flexible adjustment of the pas-teurisation units ensures a consis-tently high product quality independ-ent of the activity – overpasteurisa-tion is excluded.

The operator sets the pasteurisationunit he wants with the control. Theprogram controls the volume flow aswell as the temperature of the prod-uct. The preset pasteurisation unitsresult from the parameters tempera-ture and flow and a defined heatmaintenance section.

Even longer interruptions of the fill-ing process will not lead to an exces-sive thermal load. The plant-overlap-ping visualisation is consistentlyrealised with Zenon so that the stan-dardized touch-and-feel system clearly simplifies the operation forthe personnel.

Botec Process Control