Aseptic Bottle Filler and Capper

An aseptic bottle filler and capper is a specialized machine used in the food, beverage, pharmaceutical, and cosmetic industries to fill and seal containers with liquid products under sterile conditions, ensuring a long shelf life without preservatives. These systems maintain a sterile environment to prevent microbial contamination, making them ideal for sensitive products like juices, dairy, sauces, and sterile medications.

Aseptic Bottle Filler and Capper Video

Key Features and Process:

1. Sterilization:

   • Containers and Caps: Bottles and caps are sterilized using methods like hydrogen peroxide (H2O2), peracetic acid (PAA), UV radiation, or electron-beam technology. This ensures a high sterilization efficiency, often achieving a 5-6 log reduction in microorganisms.

   • Aseptic Chamber: The filling and capping process occurs in a sterile zone, often within a microbiological isolator, maintained with sterile air flow or steam barriers to eliminate contamination risks.

2. Filling:

   • Methods: Filling is typically volumetric or by weight, ensuring precise product volumes. Non-contact filling is common for liquids to avoid contamination, with flow rates adjusted to minimize foaming.

   • Temperature: Aseptic filling often occurs at room temperature, preserving product quality compared to hot-fill methods. This also allows for lighter, more flexible bottle designs, reducing material costs.

   • Versatility: Handles various liquids, including high- and low-acid beverages, dairy, sauces, and pharmaceuticals, with some systems supporting particles or viscous products.

3. Capping:

   • Caps are pre-sterilized and applied in the aseptic zone. The capper design isolates mechanical parts to prevent contamination, using heat barriers, diaphragms, or non-lubricated materials.

   • Servo-driven cappers or automated systems ensure precise torque for secure sealing, with some machines offering tool-less changeovers for different cap types.

4. System Design:

   • Compact and Modular: Modern systems, like combi-block machines, integrate bottle blowing, filling, and capping, reducing space and costs. Outputs range from 6,000 to 48,000 bottles/hour (based on 500ml-1L bottles).

   • Hygienic Design: Stainless steel construction with CIP/SIP modules ensures easy cleaning and maintenance.

   • Traceability: Systems record sterilization and production parameters for full traceability, meeting strict regulatory standards.

5. Applications:

   • Food and Beverage: Juices, dairy, teas, and protein drinks, enabling preservative-free products with extended shelf life.

   • Pharmaceuticals: Sterile drugs, vaccines, and solutions, requiring high precision and sterility.

   • Cosmetics: Lotions, creams, and serums, benefiting from contamination-free filling.

6. Advantages:

   • Extends shelf life without preservatives, maintaining product quality.

   • Reduces material and energy costs compared to hot-fill.

   • Supports diverse bottle sizes and materials.

   • High efficiency and automation lower labor costs and improve output.

Salient Features of Aseptic Bottle Filler and Capper

• Suitable for the filling Volume of 2ml to 250ml.

• Piston pump/Peristaltic pump aseptic filling.

• Filling accuracy of ±0.5% to ±1%.

• No cross contamination.

• Easy to validate filling system for small/large batch production.

• All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.

• Variable A.C. frequency drive for speed adjustment.

• Digital Vial Counter for counting production output.

• In-feed Turn Table/ Unscrambler for automatic feeding of objects.

• On-line Mechanism.

• “No Vial – No Filling” System.

• “No Vial – Machine Stop” System.

• IQ/OQ documentation can be provided.

• PLC system with Graphical User Interface. (Optional)

Process Operation of Aseptic Bottle Filler and Capper

The incoming dry vial (sterilized & siliconised) are fed through the unscrambler and suitably guided on the moving delrin slat conveyor belt at the required speed of the correct placement below filling unit. The filling unit consists of Filling Head, Syringes & Nozzles which are used for liquid filling. The syringes are made of Stainless Steel 316L construction and both, glass as well as Stainless Steel syringes can be used. A Star Wheel is provided which holds the vial during filling operation. A sensor is provided for ”No Vial-No Filling” operation. Syringes are mounted on eccentric block and driving through bottom main gear box. Volume can be either increased or decreased by increasing or decreasing stroke length of piston as per filling size. Syringes is having non return valve for sucking and delivering situation to avoid volume variation. Liquid will reach to filling nozzles through silicon transparent pipe. Nozzle will be having Up and Down movement with help of cam mechanism and it will come down when vial will be hold by starwheel for filling operation and starts filling when it starts to move up and after completion of filling operation, starwheel delivers six vials together on conveyor for rubber stoppering operation. Stoppering unit consist of Starwheel, Vibrator unit and Bowl. The sterilized and siliconised rubber stoppers stored in the vibrator bowl moves vertically to the rubber stopper chute. The vial is hold firmly by starwheel, which will be in continuous rotary motion and vial which is coming from filling unit get in to starwheel and move in rotary direction along with starwheel, during movement it will pick up the rubber stopper from the exit end of the chute and rubber stopper will be pressed by fix single pressing roller, which is spring loaded. Then vial further move on conveyor and collected on out feed starwheel for next sealing operation.

Technical Specification of Aseptic Bottle Filler and Capper

* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.