COMPLETE MILK BOTTLING LINE

ULTRA CLEAN VERSION

COMPLETE MILK BOTTLING LINE OFFERED BY SMF ULTRA CLEAN VERSION

SMF company offers a complete solution for dairies, supplying ULTRA CLEAN version of a bottling line for milk. The offer includes machinery and equipment such as: 1. OPTIMA Fully electric PET blow moulding machine, output up to 12000 BPH (bottle 1.0L) Additional equipment: DUMPER DR-310 preform tilter automatic preforms loading system Preform conveyor with preform orientation unit Compressor station 2. TRIBLOC RINSER FILLER CAPPER 3. LABELLING MACHINE

4. PACKAGING MACHINE Bottles are grouped in batches, wrapped with shrinking foil creating a multi-pack. 5. PALLETIZER

6. CONVEYOR SYSTEM Air and plate conveyor system.

DESCRIPTION OF MILK PREPARING PROCESS FOR BOTTLING IN ESL TECHNOLOGY

Milk plants process raw milk that they receive from farmers into marketable milk with a significantly extended shelf life. Each country has its own regulations for marketable milk production that have to be followed precisely. The quality of the processes and installations chosen will in turn of affect milk the hygienic is conditions and quality of final product. Each subsequent stage production performed carefully, hygiene and compliance are key factors which guarantee the quality of packed milk. Below is a description of milk production and filling into PET bottles by use of modern technology ESL (Extended Shelf Life), which is the best way so far to extend the shelf life of milk distributed in a cold chain. Using this technology allows you to keep both the organoleptic properties of milk, the content of microelements, vitamins and flavor, which are slightly different from raw milk. It is very important to provide the cold chain for keeping the quality of milk produced in the ESL technology. This can guarantee shelf life up to 21 days!

ADVANTAGES OF PET BOTTLES

Significantly or HDPE.

lower

weight

of

the

PET

package than other materials such as glass Cost saving production of PET bottles up to 15g per bottle. Weight of 1L PET container is only 25g, while weight of 1L HDPE container is 38-40g. No material loss during production. Lower costs due to material saving and manufacturing technology (high efficiency, low power consumption, full automation of the process). PET offers better barrier against oxygen and better protection from odours than HDPE. Possibility of producing tailor-made bottles with original shapes, attractive and esthetic for customers great marketing opportunities. PET bottles can be transparent or any other colour including white which reduces the effect of light on milk. Smooth, esthetic finish of the bottles neck, formed during preform injection no knife cut-off trace or spikes like in a HDPE. New generation of cap closure dedicated for PET bottles that prevents contamination of the product in case of multiple use (repeated opening and closing). PET is extremely lightweight and has a high shock-resistance. Its convenient for production and distribution. Transport in several layers is possible up to six layers with the right bottle design. Positive environmental profile PET can be easily recycled. Like glass, PET is a biologically inert material that doesn't react with beverages or foodstuff and is resistant to attack by microorganisms.

ADVANTAGES OF THE COMPLETE LINE OFFERED BY SMF

Professional advice and service from one contractor design, engineering, and equipment across the line Warranty and post-warranty service 24 hours /day

High Turnkey solution, adapted to the customer's requirements efficiency of OPTIMA blowing machine up to 12 000 BPH

12 000

Full automation of all sections of the production line i.e. blowing, filling, labeling. Aseptic filling provided by NON-CONTACT valves

ULTRA CLEAN Use of high quality materials version of TRIBLOCK providing protection against bacteria.

CHAPTER I

STAGES OF PREPARING THE ESL MILK FOR BOTTLING

STAGE 3

STAGES OF PREPARING THE ESL MILK FOR BOTTLING

A homogenization is the next stage of milk processing it is mechanical process in which the milk is pushed under high pressure (up to 400 atmospheres) through a device called

ESL (Extended Shelf Life) Milk is fresh milk with an extended shelf life. STAGE 1 Milk is delivered daily to the dairies, due to the high content of microorganisms in milk, it is necessary to use refrigerated storage. Milk is cooled and maintained at temperatures 4 8 C in special aseptic tanks.

homogenizer, reducing the average diameter of fatty pellets and increasing their amount (after the homogenization maximum of fatty pellets is up to 2 m). Fat is evenly dispersed. This prevents the cream from separating from the rest of the liquid once the milk is stored, milk has a better look and taste.

Aseptic tanks STAGE 2 Cooled milk is filtreted. Thanks to applying accurate biological filters the milk is free of bacteria cultures. Filtration positively effects the purity of milk. at a STAGE 4 After homogenization the milk is pasteurized temperature of 124 These on C are the in ESL technology for about 4 seconds no longer (so-called parameters endurance). and sample applied depend Homogenizer

production method. This process eliminates the activity of the enzymes catalase and peroxidase, and leads to extinction of pathogenic micro-organisms, keeping taste and nutritious properties. Microfiltration station

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The

ESL

milk

differs

from

products

existing on the market the difference is a result of the technological process. Microfiltration process - a natural method of purifying and short-time pasteurization assure ESL milk to maintain nutritional value and taste. Provided high microbiological purity results that the ESL milk does not require a treatment at high temperature. Aseptic stainless fittings

STAGE 6 Milk from the aseptic tank is delivered directly to an aseptic filler. In order to maintain sterility the air, which is used, is purified by biological filters. The filling machine is equipped with a clean room with overpressure of cleaned air inside. This is achieved by the use of fans with HEPA filters (High Efficiency Particulate Air Filter).

Pasteurizer

ADVANTAGES OF THE ESL MILK

High quality thanks to special care in every stage of the production process. ESL is a production process for obtaining milk with an extended shelf life. This method prolongs shelf life of the milk behind the period provided by traditional pasteurization. Microfiltration technology removes

STAGE 5 After pasteurization, the milk is pumped into an aseptic tank and a constant cooling temperature of 4 to 8 C is kept. Milk cannot be infected*, because it is pumped by fully aseptic valves, with an additional cushion/airbag keeping a constant pressure in the tank during pumping.

microbiological pollutants and reduces the contamination of bacteria in raw milk by *Most frequent milk infections are those from the contaminated installation where most of the bacteria accumulates causing the creation of mold. 99.99%. ESL milk has a shelf life of 21 days when stored at temperatures up to 8 C, convenient for distributors.

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CHAPTER II

COMPLETE MILK BOTTLING LINE OFFERED BY SMF ULTRA CLEAN VERSION

STRETCH BLOW MOULDING MACHINE FOR PET BOTTLE PRODUCTION Blowing machine OPTIMA Output: 1,0l 12 000 BPH TECHNICAL PARAMETERS OF OPTIMA MACHINES

Optima-4

Optima-7

Optima-8

Number of mould cavities

Bottle capacity

0,25 2,5L 0,25 2,5L 0,25 1,0L

Output Optima blowing machine Power installed

do 6000 BPH do 12000 BPH do 12000 BPH

OPTIMA SERIES ADVANTAGES

fully electric 30 50% less energy used per a blown bottle direct bottle discharge compact size use of servomotors high efficiency ceramic oven low energy consumption output over 1700 BPH per one cavity precise clamping unit with toggle system equipped with innovative technologies

75 kW

128kW

131kW

DOUBLE STAGE PRODUCTION PROCESS

OPTIMA is the machine that uses double stage production process. The first step is the preform production with the usage of PET injection machines. injection delivered machines, by Because of high cost of preforms are usually final

external

supplier.

The

package (bottle) is being made during the stretch blow moulding process with the usage of PET blowing machines like OPTIMA. It is the second stage of the whole production process:

15

orientator. Its function is to load preforms from the hopper to the gravity rails. Preforms come from the container and are thrown on rollers of the orientator. Then orientated preforms are placed on the rails that transport them directly
1. 2.

to the machine (point B). Preform container is equipped with sensors that inform about the level of preforms. The volume of the hopper enables continuous work of the machine.

3.

4.

5.

6.

1. Preform thermal softening with the usage of special oven. 2. Blowing mould opening (by closing unit) and loading of heated preform. 3. Blowing mould closing. 4. Bottle forming with the usage of high pressure air blowing and stretch bar. 5. Mould opening and ready bottle transport to exit conveyor. 6. Bottle prepared to transport to the filler by air conveyor (or other).

Preform loading from the hooper 3. GRAVITY RAILS FOR PREFORMS FEEDING Directly from the orientator, preforms are placed on the gravity rails which transport them to the machine, to the loading star of the machine.

OPERATIONAL UNITS DESCRIPTION

1. TILTER The machine is designed to automatize the production process. Thanks to this solution preforms are placed into the preform hopper automatically. 2. PREFORM LOADING SYSTEM It is independent of a mechanical container unit that consists preform (hooper),

a transport belt (conveyor) and a preform

Preforms on rails inside machine

16

4.

LOADING

STAR

AND

PREFORM

TRANSPORT CHAIN Loading star moves preforms from the rails to the place where they are loaded on the pins of the transport chain. Preforms are caught by internal holders of pins and transported in the neck up position.

Outgoing of the heated preforms 6. OVEN MANIPULATOR PREFORM MOVING TO THE BLOWING SECTION When the heated preforms get out from the oven they are taken from the transport chain by a manipulator . Working Preforms on loading star The loading star and transport chain are moved at the same time with the use of motor and belt transmission. includes: 1) Taking off the preforms from the transport chain. 2) Placing the preforms in the right position related to the position of the cavities in the closing unit. 3) Delivering preforms to the closing unit manipulator. cycle of the oven manipulator

Loading preforms on the pins 5. OVEN. With the use of transport chain preforms are transported through the process of thermal softening in the oven. Even heating on the whole surface of the preform is ensured by rotation around its axis. Rotation is carried out with a cog that cooperates with the transport chain. Oven manipulator

17

7. COOPERATION POINT OF OVEN AND CLOSING UNIT MAINULATORS In this place preforms collected from the transport chain are moved to the manipulator of closing unit which transports the preforms directly to the blowing moulds.

9. STRETCH-BLOWING UNIT Stretching bars are driven by servomotors. This solution ensures high speed and precision of their work. Operator can regulate the power and speed of stretching bars on the screen of the control panel. Stretching bars ( 12mm) are made of stainless steel. Blowing process with compressed air takes place with the use of special electrovalves. Incoming air is filtered before it comes to the bottle forming process. The machine can be also equipped with air recuperation system which enables recycling of compressed air and its second usage in the production process. It reduces workload of the compressors and saves energy consumption. Thanks to used solutions air recovery process is safe and easy to control.

Transporting preforms to closing unit 8. CLOSING UNIT AND STRETCH-

BLOWING SECTION The closing unit manipulator places heated preforms in blowing moulds. In the same time transport system based on manipulator moves the blown bottles to the exit conveyor. The operation of heated preforms loading and transport of ready bottles is periodical and takes place simultaneously (during one move of manipulator). 10. READY BOTTLE EXIT CONVEYOR The cycle of opening and closing of the blowing moulds is controlled from the control panel. The operator can adjust cycle time and speed to current situation. When the bottle production process ends, ready bottles are moved to the exit conveyor. Construction of that conveyor enables direct connection into an air conveyor (or other). Servomotor

Preforms on closing unit manipulator

Ready bottles are moved to the exit conveyor

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TRIBLOC = RINSER + FILLER + CAPPER

I. RINSER
Disinfection of PET bottles 1. Blown bottle before filling is rinsed in order to remove any possible bacteria and mold spores. 2. A solution of water with ozone is injected to the thread and wall of the bottles, which are then turned into upright

II. FILLER
4. The next stage of the production is filling of the rinsed bottle.

position. Cleaning agents: water aerated with ozone from an ozone generator water with hydrogen peroxide (H202) a 0.2% solution is most common (effective but more expensive method) 3. Obligatory rinsing with pure water takes place after cleaning. Non-contact valves 5. Rinsed PET bottle is gripped and

transported under the neck (neckholding system) to the filling valve, where aseptic filling takes place. It involves use of NONCONTACT valves located just above the neck of the bottle but not in contact with the bottle*. The milk is filled volumetrically (homogeneous product) directly into the bottle. The valves work at a constant pressure, which prevents foaming and spillage of milk. Once the specified capacity of milk is filled the valve automatically shuts off the product and the bottle is transferred to the capping machine * It is essential to prevent milk spilling on the bottle Rinser neckring, because it will cause bacteria and mold growth in a very short time after closing the container, spoiling the milk. 19

III. CAPPER
6. Caps from the main container are

LABELLING MACHINE
8. Transported bottles are detected by sensor assigning the label to each one of them, then they are directed to the star where label is placed.

orientated and transferred to the little chamber with UV lamps for sterilization to eliminate all types of bacteria.

Labelling machine

PACKAGING MACHINES
9. Labelled bottles are transported on a plate conveyor to a packaging machine. They are grouped in batches (typically 6 pieces), wrapped with shrinking foil creating a multi-pack. Milk is ready for distribution and sale. Sterilization chamber 7. Sterile caps are transported one by one, placed on the bottles and twisted. Then bottles are placed on a plate conveyor and transported to the labelling machine Wrapping with thermo-shrinking foil

Twisting the caps

Foiling with an automatic wrapper.

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CONVEYORS AIR CONVEYOR

SMF manufactures different types of

PLATE CONVEYOR

conveyors designed for complete requirements in a bottling line. Conveyors connect equipment and machinery in the bottling line, ensuring internal transport and continuous production. 1. Air conveyor Air PET bottles conveyors are designed for transporting empty PET bottles between the PET blowing machine OPTIMA and the first section of the TRIBLOCK RINSER. Single bottles are transported linearly at high speed, held at the necks so there is no problem with stability. The line is equipped with adjustable guard-rail which enables work with different bottles design. Air conveyor system is also equipped with damping exit which is opened pneumatically to eliminate defective bottles from production. Multi row plate conveyor 2. Plate conveyors Plate conveyors are designed for transfer of filled bottles from TRIBLOC to labelling

machine and to packaging machine. All the conveyors may have single or multirow construction, are available in straight and curve parts and provide horizontal transport as well as transport in an angle. Both plate and air conveyor have a modular construction. They are easy to adapt to the variable and evolving infrastructure of the production line.

Air conveyor

Vacuum conveyor

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CHAPTER III

SUMMARY

COMPLETE MILK BOTTLING LINE consists of:

CONDITIONS TO PROVIDE LONG SHELF LIFE OF THE ESL MILK

1. OPTIMA 7 fully electric PET blow moulding machine, output up to 12 000 BPH (bottle 1.0L)

It is very important to provide the cold chain for keeping the quality of milk produced in the ESL technology. This can guarantee shelf life up to 21 days!

2.

TRIBLOC

(RINSER

FILLER

+ Any interruption of the continuity of the cold chain in any of the stages of production causes shortening of the time of expiry or spoiling of the entire batches of milk exposing the

CAPPER) Ultra clean version offered by SMF assures high hygienic conditions. All machine parts are made from high quality materials that are suitable for contact with the liquid (milk) securing health safety and high resistance against corrosion, bacteria and mold spores .

manufacturer to a loss and excessive costs. The maximum shelf life of ESL milk when the cold chain is kept is 28 days

The ULTRA CLEAN version also means that the machine has a clean room with

overpressure of purified air inside. This is achieved thanks to fans with HEPA filters.

* it is also possible to use biological filters, which need to be sterilized once a week (effective and more expensive solution)

3. Labelling machine

4. Packaging machine

5. Palletizer

6. Conveyors

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SMF in Benelux, France Rue Lacherez, 25 bte 6 6150 Anderlues, Benelux tel. +32 719 633 80 tel. +32 227 268 32 cell: +32 498 111 362 (Benelux) cell: +33 609 147 463 (France) SMF in Colombia, Venezuela Carrera 97 No.24C - 75 Bodega 42, Bogota, Colombia tel. +57 1 422 3164 fax: +57 1 267 27 50 SMF in Czech Republic, Slovakia Struzena 1684 39301 Pelhrimov, Czech Republic tel. +420 775 108 502 fax +420 775 108 502

SMF in Iran 16 Shervan Alley, Vali-e-Asr St., Tehran, Iran tel. +98 21 8888 07 36 fax: +98 21 8888 95 25

SMF in Poland Kunicza 17 21-045 widnik, Poland tel. +48 81 751 67 14 fax: +48 81 751 21 04

SMF in Jordan, Lebanon, Iraq 62 Nables St.- Jabal al Hussain Amman, Jordan tel. +962 656 219 36 fax: +962 656 833 77 SMF in Mexico KOPOMA MZN 95 LT 5, Col. Pedregal de San Nicolas Deleg. Tlalpan CP. 14100 Mexico DF tel. +52 56 88 97 17 fax: +52 56 31 14 22

SMF in Tunisia 118, Rue Abou Rayhan Bayrouni 2050 Hammam- Lif, Tunisia tel. +216 71 210 670 tel. +216 71 299 566 SMF in USA, Canada 14939 NW 27th Ave. FL 33054 Opa-Locka, USA tel. +1 305-687-1171 fax: +1 305-687-1174

SMF GmbH Redcar Str. 40 D-53842 Troisdorf-Spich Germany tel.: +49 2241 944 886-0 fax +49 2241 944 886-99 [email protected] www.smfgmbh.com