Aseptic Spouted Pouch Fillers A300 for high and lowacid food products with extended shelf life

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Aseptic Spouted Pouch Fillers A-300 for high
and low-acid food productswith extended shelf
life
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Aseptis whos who

• Aseptis was set up in 2004 following a
  technological transfer from the Spanish company
  Bossar s.l., as a worldwide leading pouch
  machinery manufacturer, together with the
  incorporation of skilled people as a competence
  transfer. Our Aseptis technical office has
  redesigned a well-proven technology to release a
  new generation of horizontal stand up pouch
  equipment copying with the state-of-the-art
  sanitary and hygienic design standards. It leads
  us to expand market segments for flexible
  containers like ultra-clean and aseptic
  packaging.
• Every model stands strictly its users
  requirements as well as its relevant
  microbiological validation protocol. Our
  technical expertise, powered by alliances made
  with third parties expert in containment system
  and disinfection system, guarantee long shelf
  life to both high and low-acid cold filling
  products. You can visit us at www.aseptis.com

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Aseptis machinery

• Since 2006 Aseptis has his first aseptic machine
  working with success ? A-300
• This machine is dedicated to fill compote under
  aseptic conditions

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Our flexible spouted package

• A tight package for liquid products with or
  without particles
• Multi-sizes available
• Medium output development

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Spout and Screw Cap Design Examples

• Tamper evident remains on the base
• ALU seal (optional)
• Minimum dead corners
• Easy opening

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Beverages on-the-go markets

• for children
• UHT flavored milk
• Soy based drinks
• Teas
• Sports beverages
• 100 per cent juice
• Flavored water
• and for the others
• Coffee milk
• RTD soups
• Medical solutions

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Sterilization operations

• Sterilization of packaging materials
• Sterilization of our packaging machine
• Maintaining sterility in our packaging machine

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Sterilization of packaging materials
Application of isolator technology for

• SPOUT LDPE or HDPE
• Dry Sterilization gas H2O2 as sterilant (both
  interior and exterior)
• FILM/POUCH PET/ALU/LLDPE
• Dry Sterilization gas H2O2 as sterilant (both
  interior and exterior)

• Sterilization level
• ASEPTIC Reduction 6-log Bacillus Subtilis
  germs
• H2O2 residues lt 0.5 ppm

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Chemical disinfecting agent vaporized H2O2 Dry
sterilization

• Spermicidal at low gas concentration
• Quick sterilization, short cycle times
• Low level of chemical residual
• Excellent material compatibility

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Film internal sterilization Aseptis patent
pending
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Pouch internal/external sterilization
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Sterilization methods for our packaging machine

• The pouch packaging machine gaseous H2O2, which
  does not condensed at the surface of the machine
  
• The filler steam or liquid chemicals sterilants
• The air filters Hepa filters in Rabs/laminar
  flow systems are sterilized by H2O2, to prevent
  issues when starting or after replacement of
  filters.

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Maintaining sterility in our packaging machine

• Our aseptic pouch fillers have to be
  sterilized prior to production and kept in
  sterile condition during production. We have two
  ventilation methods for protecting aseptic zones
  by sterile air
• Protection of larger zones by restricted access
  barrier system (RABS) with vertical laminar flow
  like
• the pouch forming area, starting from the film
  sterilization up to the pouch cut-off
• the pouch filling area
• For the production of sensitive products, this
  covered machine is installed in a clean room.
•  
• Protection of critical zones by a containment
  cabin (ISOLATOR) with turbulent ventilation
• the pouch filling area with overpressure
• the packaging material sterilizing area (film,
  pouch, spout) with negative pressure
• All enclosure surfaces, also those of pouches,
  must be sterile because the micro organisms may
  be carried around inside such a totally closed
  system.

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Isolator Functional Principles

• The immediate containment of the working area
• The air and surface treatment
• Fan and HEPA filter modules,
• Pressure regulation
• Sterilisation system
• The handling by the operators
• Doors and sleeves fitted with gloves for local
  intervention

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Isolator Ventilation and Filtration
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Machine features
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Pouch Dimensions - Volume
Examples
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Operating Diagram A-300
POUCH MAKER 0- Automatic reel splicer
(Optional) 1- Reel unwinder 2- Bottom pouch
sterilisation 3- Bottom sealer 4- 1st vertical
sealer 5- 2nd vertical sealer 6- Cooling unit
7- Free station bottom/top round corner 8-
Master pulling unit 9- Scissors 10- Selection
and validation
POUCH FILLER 1- Opening by hot sterile air 2-
Blowing cones by hot sterile air 3- H2O2
injection 4- H202 Aeration 5- Filling
station 6- Stretching optional N2 injection
7- Top spout inserting1st top sealing station
8- 2nd top sealing station 9- Cooling unit 10-
Exitrejection ramp
Aseptis patent pending
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Unwinder QC System

• The unwinder design accepts one or two reel
  supports
• Expansible pneumatic reel shaft for quick
  changeover ? Possibility to integrate an
  automatic film splicer to avoid loosing any time
  in film changeover and to increase machine
  efficiency
• Proportional brake according to unwinding film
  tension
• Splicing table with automatic brake in ergonomic
  position
• Continuous servo motorized rollers with tension
  control
• Buffer lever to keep independent continuous
  unwinding from intermittent motion on following
  stations
• The film is constantly laterally guided during
  unwinding
• A photocell reads the printed eye mark for
  positioning the film under two double bottom hole
  punchers
• Retails go to a collecting box

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Unwinder QC System

• Film tracking composed by one group with triple
  function
• Slave pulling rubber servo motorised pulling
  rollers, which are synchronised with main pulling
  system. It leads to further film transportation
  in the sealing area under tension control
• Hole punching adjustment synchronised with the
  photocell, the adjustment of the film for the
  cutting dies is made by the servo rollers
• Automatic film alignment composed by guiding
  rollers which are laterally orientated by a
  servomotor according to the photocell signals to
  get a correct position of the film on the forming
  plough entrance
• Motorized height and gusset adjustments (no spare
  parts)
• System guarantees a tolerance of 0,25mm.

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Unwinder layout and picture
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Sealing QC system

• All the sealing groups have P.I.D control heating
• The independent and removable bottom and vertical
  lineal sealing jaws are mounted on a plate which
  allows their horizontal adjustment, cycle by
  cycle, according to the photocell signal at the
  entrance. It leads to a constant relocation of
  the sealing jaws according to film spot
  variations (automatic seal alignment).
• Motorized lateral movements of sealing groups
  (easy format change)
• Vertical sealing jaws are composed by a rigid
  flexible (silicon) side.
• A master and slave pulling system brings a
  uniform film tension in the sealing area avoiding
  any stretching.
• The servo motorized rubber rollers, with the
  assistance of the lineal movement holding
  gripper, pulls the film without creating any
  tension.
• A photocell close to the pulling system brings
  high cutting accuracy.
• System guarantees a tolerance of 0,25mm seal
  width.

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Sealing Parameters Controls and Safety Back Ups

• Development of recipe (heat/time/pressure)
  critical to seals quality

Seal Temperature The design of the sealing
heads and the control system must be capable of
delivering a temperature variation of less than
4C on the sealing bars. Visual display and
automatic machine alarm or shutdown if
temperature outside limits (e.g. 6 C) Seal
Time The seal time is dependent of the machine
cycle.Optionally, it is possible to make it
independent if required on time Seal Pressure
This system must deliver pressures to obtain high
quality seals. The system must be reliable and
capable of delivering a repeatable result over
long periods of time. Transducers record sealing
pressure on each head. Optional visual display
and automatic machine shutdown if pressure below
acceptable limits
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Sealing Group

• Mechanical movement and independent bottom and
  vertical sealing units
• Lineal movement of the sealing units creates
  high-pressure sealing up to 1500 kg force

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Mechanical Design Oriented to the Operator

• Machine backside easy to access for maintenance
• External machine Stainless Steel 304
• Cinematic based on the equilibrium law
• Internal mechanisms in Carbon Steel treated with
  Zinc
• IP 65 rating. Suitable where high pressure wash
  downs are required.

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Mechanical Design Oriented to the Operator
Inner cam for complete inertia control and lower
maintenance (no spring)
Central lubrication for constant maintenance
Weight Compensator
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Optimized Pneumatic System
Communication between modular electrical unit and
Siemens PLC by Profibus for wiring reduction
Modular unit located close to operated group for
quicker response
In-frame pressure feeding system
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Pouch Filler

• Sanitary design of the complete filling system
• All product contact parts in Stainless Steel AISI
  316L
• CIP and SIP application
• Types of fillers
• Inductive flow-meter
• Non-inductive flow-meter (mass flow meter)
• Volumetric piston pump
• Analogical or digital level detector
• Types of filling nozzles non-drip, cut-off

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Filling System
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CIP SIP Hygienic Design
CIP Collectors
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Pouch Transport System Aseptis patent pending
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Spout Transport System Aseptis patent pending
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Spout inserting sanitary gripper
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• 2 Alternatives for filling zone
• A-300

RABS ISO
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Machine Layout A-300 RABS Front View
Pouch Decontamination Tunnel
Reel Unwinder
Film decontamination unit
Pouch Maker RABS
Pouch Filler RABS
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Machine Layout A-300 RABS Top View
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A-300 RABS
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A-300 RABS
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Machine Layout A-300 ISO Front View
Pouch Decontamination Tunnel
Pouch Filler ISOLATOR
Film decontamination unit
Reel Unwinder
Pouch Maker RABS
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Machine Layout A-300 ISO Top View
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A-300 ISO Machine sketch
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A-300 RABS Process Flow Diagram Production Phase
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A-300 ISO Process Flow Diagram Production Phase
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Aseptic Spouted Pouch Fillers A-300 for high
and low-acid food productswith extended shelf
life