Integrated process makes operation easier

The Krones company integrates all peripheral process technologies and effectively links aseptic filling machines, CIP equipment, sterile water production, product mixing, product cleaning, disinfection and disposal into a series of productions, fully solving the links caused by external products. problem. Krones integrates the process technology with the aseptic filling process of PET bottles. The operation method is the same and the visual management is unified. The process of production is effectively controlled and the operation is facilitated.
The “fine modulation” (ie, enhanced research and continued development) of the PET bottle L sterilization method shows that the system sterilization method is not only not out of date, but is still the correct method for a variety of applications. Therefore, the peracetic acid sterilization method is fully qualified to stand in aseptic filling production.
So, under what circumstances is it recommended to use PET bottle hydrogen peroxide D dry sterilization method? Experience tells us that there are the following three conditions: First, the milk processing industry has long been popularized by hydrogen peroxide sterilization; Second, customers want to change the soft packaging to a sterile PET bottle packaging due to market demand; Third, familiar with and used hydrogen peroxide as a disinfectant The carton filling company.
The third case is for companies that want to reduce the cost of water. According to the Krones method, the use of hydrogen peroxide dry sterilization eliminates the need for post-rinsing the bottle, thus avoiding additional water consumption.

Hydrogen peroxide sterilization without condensation

This hydrogen peroxide sterilization method is not a conventional hydrogen peroxide sterilization method. When using this method, it is necessary to first dribble the hydrogen peroxide onto a heated surface to cause it to vaporize and activate, and then remove the vaporized hydrogen peroxide gas by the hot gas flow. The air saturated with hydrogen peroxide is blown into the preheated bottle, and the surface of the bottle is disinfected, and the air (<0,5 ppm H2O2) without residual hydrogen peroxide is blown out of the bottle. Due to the efficacy of hydrogen peroxide gasification, the log 5 sterilization effect of Bacillus subtilis can be quickly achieved. Another advantage of the Krones Sterilization method is that the gasification step is completed before entering the container.

Wet sterilization reduces production costs

In addition to the development of two new sterilization methods "D" and "FDA," Krones has also improved traditional L sterilization in important aspects such as production cost and consumption data, reliability and hygienic design, process and adjustment time. Method to reduce production costs by reducing media consumption.
Secondly, by improving the details of the construction, the security and filling effect of the entire system are greatly improved. In this regard, the Krones company needs to specifically handle the hygiene design to meet the high requirements of the equipment operators in both microbiology and technology. The construction of equipment that meets hygienic design has many advantages in terms of economic benefits: improved reliability of filling effects, saving on the use of detergents, and reducing the cleaning time that cannot be overlooked. Especially when using sterile equipment, production interruptions caused by CIP cleaning or manual cleaning can reduce the production efficiency of the entire filling line.

Impact of Packaging Materials on Production Costs

In comparison, the condensing hydrogen peroxide sterilization method can only reduce bottle weight to a limited extent. When using the condensing hydrogen peroxide sterilization method, the relationship between sterilization effect, bottle shrinkage, and hydrogen peroxide residue should be considered, and compromises should be taken. Since the heating temperature of hydrogen peroxide is very high, the bottle must have considerable stability, that is, more PET material is needed to make the bottle.
To increase the impact of PET materials on the production cost of a filled bottle, the following can be used as an example for the full-line digital production of 3,600 bottles:
Taking the power consumption and production medium consumption (steam, water, and working air) of a Nordic factory as an example, the electricity cost per 1,000 bottles using Krones PET bottle L sterilization method is 0.9 Euro, and the use of Krones PET bottles D The electricity cost of the sterilization method and the hydrogen peroxide condensation system sterilization method is 1.3 euros. In terms of media consumption, the dry sterilization method is rather optimistic: the medium consumption cost of the wet sterilization method is 1.3 euros, and the medium consumption cost of the dry sterilization method and the sterilizing system sterilization method is 1.0 euro.
However, among all the factors that affect the production cost, the material consumption is still the largest: based on the lighter 1.5 litre disposable PET bottle (28 mm diameter, 34 g bottle weight), the sterilization must simultaneously reach the minimum shrinkage of the container (less than the rated volume). 1%) and the lowest residual (< 0.5 ppm) standard for hydrogen peroxide, for every 1000 filled, labeled, packaged bottles, the Krones dry and wet system sterilizes at a cost of €119.45. .
If sterilization is performed using the hydrogen peroxide condensing system sterilization method, and to achieve the same sterilization effect and residual and shrinkage, the weight of the bottle is at least 37 grams. For every 1000 bottles, the cost is 124.33 euros.
This calculated result shows that the material consumption between Krones non-condensing hydrogen peroxide dry sterilization (PET bottle D sterilization method) and peracetic acid wet sterilization method (PET bottle L sterilization method) is not very different. But in terms of electricity consumption and water consumption, there are advantages. Since the hydrogen peroxide evaporation time required for the condensing hydrogen peroxide sterilizing method is relatively long and the corresponding machines to be put in are also large, in particular, the consumed PET bottle material must be increased, resulting in an increase in cost. With 1.5 billion fillings, if the weight of each bottle is increased by 3 grams, the annual cost will increase by about 73,200 Euros. This example clearly shows that packaging materials have a large impact on the cost of production. In contrast, the impact of energy consumption and media consumption on production costs ranks second only.

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