V-Brew has teamed up with Sraml, a leading provider of cutting-edge processing equipment to deliver our customers the most efficient Automatic Bottling/Canning solutions. Our Sraml Monoblock system, which is a set of different machines combined into one block, is particularly popular. These systems require significantly less space and personnel, optimise energy consumption, and perfectly synchronise units for increased productivity.
Within this article, we are going to discuss the filling process in greater detail, to give you more of an understanding of how our Sraml Monoblock Systems work. Keep reading to find out more.
What Are Counter Pressure Fillers?
Counter pressure fillers are a key component of monoblock systems, which are used to smoothly fill glass bottles, plastic bottles and aluminium cans, as well as different closure systems including:
- Cork
- T-Cap
- Pre-threaded Cap
- Crown Cap
- Pressure-cap Closure
These fillers are amongst the most advanced available on the market, with the ability to meet your company’s individual needs, whether you are wanting to bottle 1,000 pharmaceutical products per hour, or 20,000 drinks.
What Are The Key Features Of Counter Pressure Fillers?
V-Brew’s counter pressure bottles and can fillers have several advanced capabilities, that are in place to ensure product levels remain consistent and product agitation is minimised, for example:
- They are suitable for filling carbonated or still liquids, hot or cold, into aluminium/PET cans or glass bottles
- The individual filling steps are mechanically operated with cams
- The filler has a rotating carousel, a pressure bowl and a set of filling valves, which allow it to fill multiple cans or bottles at the same time in a continuous motion, without stopping
- To minimise agitation, the product is fed into the pressure bowl from the bottom to ensure improved emptying
In addition, the counter pressure fillers use a sophisticated technology to provide the operator with maximum control and ease of use. For example, the built-in touchscreen control panel will allow the user to choose the exact starting and stopping point of the product inflow, and when the minimum product level hasn’t been reached, the system will alarm the operator and will halt the filling sequence. More technical features of these fillers include:
- An electrical motor to allow for simple and faster adjusting of filler height, without any locking mechanism or tools
- A built-in digital pressure sensor to precisely maintain the set pressure inside the tolerance
- Straightforward changeover between aluminium cans and glass bottles, as only the filling tubes and centering bells need replacing
How Does Bottle Filling Work?
The bottle filling can be a complex process, so here’s a breakdown of its method of operation:
- The bottle is transported to the filling position with the help of a star wheel. The filling position consists of a pneumatic bottle-lifting piston and the counter-pressure filling valve, mounted on the pressure tank. The piston lifts the bottle and makes a tight seal with the filling valve by pressing the bottleneck against the rubber on the valve.
- When the bottle is in the filling position and sealed with the valve, the vacuum is activated to evacuate the air in the bottle. Vacuuming is activated by the cam mechanically pressing the vacuum button on the filling valve.
- The vacuumed bottles are then injected with CO2 gas. When filling in deaerated bottled, the product is exposed to the CO2 gas only, reducing the oxygen absorption. The vacuuming-CO2 injection of the bottle is repeated two times, in order to have a complete evacuation of the air.
- After the bottle is pressurized with CO2 gas, the product pouring can start. The filler is equipped with a “no-bottle, no-fill system”, which won’t activate filling if no bottle is detected in the filling position.
- When product pouring is completed then the filling valve closes
- Filled bottle is carefully depressurized, via the shift button, preventing product fobbing.
- After the filling process is completed, the piston is lowered and the bottle is transported with the help of a star wheel.
How Does Can Filling Work?
- The aluminium can is transported to the filling position with the help of a star wheel. The filling position consists of the counter-pressure filling valve, mounted on the pressure tank.
- When the can is in the filling position the CO2 injection will be activated and flushed, to replace the air with CO2 gas. When filling in inerted cans, the product is exposed to the CO2 gas only, reducing the oxygen absorption. At the same time of injection, the valve centering bell is lowered and a tight fit is made between the can and filling valve.
- After the can is pressurized with CO2 gas, the product pouring can start. The filler is equipped with a “no-can, no-fill system”, which will not activate filling if no can is detected on the filling position.
- When product pouring is completed then the filling valve closes.
- Filled can is carefully depressurized, via the shift button, preventing product fobbing.
- The centering bell of the valve is being lifted with the help of a mechanical cam, and filled cans are transported with the help of a star wheel.
Automatic Filling Solutions From V-Brew
V-Brew’s team of engineers are experts in the sizing and installation of monoblock systems, flash and tunnel pasteurisers, whilst providing a highly efficient, personalised service to deliver our customers the best results, according to their specific requirements.
V-Brew has the experience to get the most out of your filling line. If you wish to have a conversation about your individual needs with our esteemed team please do not hesitate to contact us via e-mail address info@v-brew.co.uk. We are keen to discuss your current set-up and how you can improve your products in the future.
