With the blowing-filling-capping combiblock technology becoming more and more mature, PET bottled filling for CSD beverage also develops along that trend with the potential of energy conservation and emission reduction. All the time, Newamstar has concentrated on exploring reliable, efficient and low energy consumption filling technology. There is no doubt that room temperature filling will be the most effective filling method. The CSD beverage contains CO2, so CSD combiblock is distinctly different from water combiblock. What is more, the development of filling valve is more difficult.
During operation, the preform is blew into empty bottle by blow molding machine, handling by mechanical grippers and transiting by star wheel to filling machine. As the work environment of filling machine and blow molding machine is totally different with mutual interference, the filling machine is wet region,which requires lower work temperature, while the blowing-molding machine is heat source region, which requires dry environment.In this way, there needs adapter module region to seperate the blow molding machine and filling machine. In that region, there is only one gap for bottle in and out in order to guarantee a sealing state. The FFU, at the top of filling machine, provides clean positive pressure airflow to separate air and avoid steam and hot wind from crossflowing. The following drawing shows that blow molding machine and filling machine need the buffer region for transition.
When empty bottle passes from transition region and several star wheels to filling machine, during this period, we must cool the bottle bottom down to make sure the filling quality.
The preform is blew into bottle by blow molding machine with higher temperature. When filling CSD product, the product tepmerature is a little bit low and the blended CO2 is quite unstable. The temperature of bottle bottom must be reduced from 60～70℃ to 40～50℃ to avoid hot temperature influencing filled product and causing foam. Under the star wheel between blow molding machine and filling machine, there are some showering and cooling nozzles to cool the bottle bottom by water. The nozzle quantity is decided by filling speed and bottle combination configuration. Through trials demonstration, it requires 5 seconds cooling time to achieve the effect. The actual cooling zoon is designed by no more than 8 seconds to treat bottles with different bottom quantities and sizes. As to the design of nozzle, in order to ensure large cooling surface, it adopts high effective mist spraying nozzles, which can largely save water consumption. In addition, we can recycle cooling water to save energy and reduce emmission according to customer’s requirement.
After cooling the empty bottle, the bottle will be transferred to filling machine, the filling valve starts to work. As the most important core part of filling machine, we prefer to recommend customer to use electromagnetic flowmeter electrovalve. The filling process between traditional mechanical isobaric filling valve and electromagnetic flowmeter electro-isobaric filling valve are quite similar. The difference is that mechanical valve adopts actuator to complete all filling motions according to installation sites, while the electrovalve can realize automatically control according to time order through electric procedure. Therefore, even though the operation speed changes, the electrovalve still can automatically operate according to set ruuning time to satisfy constant filling state, which also make sure filling quality and precision. Compared to mechanical valve, with precise control and realiable execution, electrovalve will better statisfy design requirement of high quality, high efficiency, low consumption and intensification. Nowadays, there is significant breakthrough on structure and function of newly developped filling valve from Newamstar.
The lifting air cylinder and valve are designed into one part with simple structure and easy to clean. Saving the single lifting air cylinder srtructure will reduce maintenance cost and increase equipment’s reliablity. By optimizing inner valve’s structure to provide fluid passageway a simple, clean, placid and easy cleaning state. Except CSD, the filling valve also suits for the filling of mineral water and juice beverage.
According to different products, the flowmeter electro-isobaric filling valve also use different filling model design to control the filling precision, with the sequence of slow filling, fast filling and slow filling to control filling precision, with the advantage of stablizing filling product, avoiding foam, enhancing filling temperature, realizing room temperature filling for CSD and saving energy consumption.
Electrovalve is specially designed with screw type filling method, and the product is filled equally along inner surface of, which is better for CO2 to be blended into product, ensure a moderate filling process and less foam, especially it is suitable for high temperature CSD beverage which is foaming easily. Besides, when the back washing function for valve chamber is in operation, the by-path will open to increase the diameter of washing passageway, the problem of CIP wash in the small air emission chamber is no longer exist, meanwhile it also enhance washing effect. Every filling head is equipped with a dummy cup, and customer can choose manually or automatically according to their needs.
In order to further ensure the filling quality, the PID adjustment is adopted to control the filling stability of the product-in, pressure preparation and air emmission outside filling machine. Especially to maintain the presure after the collection from air emmission chamber, it can help control the stability of air emmission, particularly for CSD filling with higher temperature.
After filling, the filled bottle will be transferred to capping machine by star wheel. The design of capping machine suits for different kinds of caps. According to the requirement of carbonated beverage cap or drinking water cap, the differential D-C electric motor on the top can be directly adjusted on the touch panel, different caps just need to precisely adjust capping rounds. Of course, regarding to the cap cleaning, except the normal disinfectant spraying, according to customer’s configuration requirement, we can also instal middle pressure UV sterilization device on the cap dropping guide rail or ozone air blowing device to meet customer’s different cap treatment needs.
In the actual production, customer sometimes needs to change many types of bottles from 250ml to 2.5L in one production line on the basis of market situation. Therefore, adopting quick changeover is very necessary. The new type of changeover structure can shorten nearly half work time and enhance production efficiency.
Besides, with the widely use of electromagnetic valve and diaphragm valve, high electromechanical assorted level is indeed required. Integrating controlling system and in-line inspection system, comprehensively applying optics, mechanical, electricity, pneumatic and liquid,etc., integrating image recognition technology and applying servo system to realize synchronous control to help customer realize many single unit’s equipment become integrated control and production, meet all kinds of beverage production needs, achieve the purpose of one machine for different products, realize scientific layout design of production line, seamless joint and integrated control, reduce investment cost, lower energy consumption and decrease maintenance cost. By comparision with traditional filling method, combiblock with electromagnetic filling valve has more advantages in the key indexes of energy saving, emission reducing, filling precision and realiability, future prospects are very bright.
NEWAMSTAR HIGH-SPEED BLOWING-FILLING-CAPPING COMBIBLOCK
Newamstar High-speed Blowing-filling-capping Combiblock combines the blowing system, filling system and capping system in one integrated system, reducing several intermediaries suchas transmission, empty bottle handling and storage processes, which improves packaging hygienic condition and reduces packaging ross-contamination so as to improve the overall operating efficiencybut lower the energy consumption, thereby reduces the overall production cost of enterprises
- Product Range: Production capacity from 12,000 BPH to 80,000 BPH.
- Applications: It is applied to PET bottled pure water, carbonated soft drink, juice, liquid dairy, liquid condiment and household & personal care products, etc.
Stable infrared ray heating system and independent heat balance device ensure the stable temperature of the preform, even color of the bottle and increase of the output.
Special designed twice-blowing system can monitor the pressure in each mold in order to provide accurate real-time parameter for operator. It is easy for the operator to adjust the parameter and ensure the stability of bottle forming.
High-speed and high-accuracy diaphragm type filling valve: Equip air back channel which is separated from liquid carousel, by which, the air replaced from the PET bottle won’t enter liquid carousel to avoid second pollution. Equip cleaning dummy bottles which can realize online CIP.
Sanitary and washable capper：Optimized cam surface design ensures the minimum
impact force of the capper .Bottle discharging starwheel is screwing decently, so it is unnecessary to adjust the conveyor height during bottle format change.
Driven by innovation and win the market by quality!
Newamstar has focused on liquid packaging industry since from its establishment. Taking innovation as guide and basis, we have been forging ahead constantly.
As an outstanding company in China high-end equipment industry, Newamstar has built a dimensional product system gradually including beverage, milk, alcohol, condiment and daily used chemicals. We have won many innovative “China First” for various products. All these achievements and milestones will be fixed and memorized in the long history of Newamstar.
INTELLIGENT STEREOSCOPIC WAREHOUSE SYSTEM: THE FIRST CHOICE OF BEVERAGE FACTORY TO UPGRADE THE MODERN WAREHOUSING AND LOGISTICS!
In recent years, with the increasing of automation and production capacity of liquid food packing line, contradictions between inventory and production capacity have become increasingly prominent. At the same time, with the increase of land cost and labor cost,traditional discrete model of warehousing and logistics using single logistics equipment or personnel to carry out the transportation of product and raw materials has been outdated.
With the deepening of “industry 4.0” and “Internet +” concept, the Chinese industry is transforming from the traditional labor-intensive to the industrial automation, and the traditional management mode based on people is turning to computer-based Information and modern management. Intelligent equipment represented by robot and a new generation oflogistics model with the function of data collection, management and data tracing is being more widely used in the market.
As the Chinese leader in the field of liquid packaging, Newamstar accumulated rich experience in long-term development. By industry research, product technology development and the integration of industry resources over one year, Newamstar introduced the concept of “Internet +” into the production line followed by the pace of “Industry 4.0”. On the basis of rising the capacity and stability of liquid packaging production line, Newamstaroptimized the structure of production lines and improved the level of automation of the production line by reducing the cost, and improving the quality and efficiency.
- Goods transition and storage – high rise shelf, tray and container.
- Check in & out device – palletizer.
- Check in & out distribution system – roller and chain conveyor, distributing vehicle, lifter, etc.
- WCS control system – includes check in-out device controlled by computer, distribution system, various kinds of inspection and safety device controlled by electricity.
- WMS warehouse management system – warehouse account management, data analyzing, goods site arrangement, device operation and warehouse storage display, etc.
A double extension tunnel stacking machine is adopted in the projects of“Moon over a Fountain Co. Ltd”, which achieve an effective balance between capacity and efficiency by improving space utilization and flexibility of warehousing in a limited space. The production line is connected with the warehouse directly, so a lot of material transfer links was saved. With advance internet technology, it realizes the resources and data sharing and connection between the ERP(enterprise resource management system), MES (manufacturing execution system) and WMS (warehouse management system) to reduce the mistakes and speed up access of the goods. Compared with the traditional discrete warehouse, Intelligent stereoscopic warehouse system can save the cost of land investment, reduce labor intensity, improve the working environment and reduce labor costs, finally improve the production efficiency and the level of modern management by making packaging and storage systemIntegrated, automated and intelligent.
In 2015, with excellent R&D design team and processing advantages of equipment manufacturing, Newamstar completed the development of automated warehouse system with tunnel stackerand RGV rail transport trolley. In the same year, Newamstar successfully presented it on CBST exhibition in Shanghai, and received wide attention from lots of companies in the industry. In 2016, automated material transport under special circumstances is solved by researching and developing non-rail AGV transport trolley. Through the introduction of advanced visual logistics simulation software FlexSimand excellent simulation designers, we can make simulation test in the project planning process, and do all kinds of system analysis and engineering verification for the model to get the final optimized the design. It can also quickly confirm the logistic equipment solution, further verify the feasibility of the project, provide improving and management basic data for the system, and reduce operating costs of production enterprises.
Currently, Newamstar are upgrading internal logistic systembased on stereoscopic warehouse system, will build automated logistics system by using AGV non-rail Intelligent trolley to distribute the raw materials, and create a new automated management system with the product lifecycle management, process management and information management.
New age, a new chapter, a new dream. With the evolution and promotion of intelligent stereoscopic warehouse system, it will help beverage manufacturers to clarify and refine requirements, quantify data target and accuracy control of the production process, and finally help to realize the intelligent, automation and modernization of plant.