Transportation of Oriented Caps under Aseptic Conditions
At this year’s BRAU, cap feeding system specialist GASSNER presents some new components for feeding pre-oriented caps under both normal and aseptic conditions. VertiLift is an innovative facility which opens up new possibilities for cap transportation by conveying caps vertically upwards, thus creating flexibility as regards the configuration of the bottling line as a whole.
The starting-point for all the design considerations was a customer request, due to stricter hygiene requirements and associated aseptic and clean room concepts, to have the caps oriented not directly above the capping machine but slightly to the side of the central bottling area. This has the advantage that less abrasion and dirt occur in the clean area. In addition, the oriented caps can undergo sterilising or aseptic treatment during onward conveying. In recent years GASSNER has already presented a whole series of systems, such as the DynaSort orienting elevator family, horizontal conveyors with a special guide cage and a variety of sterilizing equipment.
The latest system introduced, VertiLift, offers an improved solution for upward transportation of oriented caps. It can carry the caps vertically upwards, thus travelling from storey to storey, e.g. from the basement to the bottling area. The system comprises an enclosed chain case at the back and a conveying area at the front which is designed for easy access and cleaning. Caps are transported securely and gently upwards with the aid of precision carriers, each in a separate pocket, in single file.
The whole construction is rugged and built for long life, designed for round-the-clock operation on a shift working basis. With regard to transportation of pre-sterilised caps, all the components are selected to be resistant to the disinfectant used (e.g. H2O2). The whole system can also be placed in a protective atmosphere by agreement with the customer. The result is greater flexibility for line layout. Any make of cap disinfecting unit can now be positioned on the floor, next to the enclosed bottling line. Specific complete solutions for all cap feed applications are developed for customers and fully integrated into the wide standard range of GASSNER cap feeding systems. GASSNER always has the right solution.
On the BRAU´99 fare Gassner, the specialist for cap feeding systems, present a new generation of elevators designed to feed and orient plastic or aluminum caps. Due to the innovative solution of making the heigth of the carriers variable, for the first time one unit for different heights of caps could be realized. The changing of format parts becomes obsolete, when changing caps all work of adjustment is reduced to a few seconds.
Even in respect of robustness and durability no compromise was made. On top of the obligatory use of stainless steel a mentainance free chain of plastic and stainless steel is also used, which makes unhygienic grease redundant.
The result is a maintenance free unit with universal layout for different heigths of caps and feeding speeds, for big sized wide heels caps up to standard screw caps; it also works up to the highest standards of hygiene. Moreover, with DynaSort the demand can be met to orient the caps outside a clean room, and to hand them on to the capper in a queue.
By the full integration of the DynaSort into the large Gassner standard program you get tailormade systems. For each situation a perfect cap feeding solution can be offered.
For standard screw-caps and Push-Pull (sports cap)
Gassner, the specialist for cap feeding systems, has changed now all orienting elevators for standard screw caps and Push-Pull caps (sports cap) to the innovative principle of the DynaSort family. These Units are ideal when non carbonated and/or juicy or milky drinks are filled in PET or glass bottles, and a plastic cap is used.
Wether the filling area is opened or sheltered by a housing or a clean room, all caps are oriented by the orienting elevator, removed from the closing machine. Once oriented they are fed by hygienic special conveyors and handed over to the closing machine by stainless steeel chutes. Due to the absence of a rotating hopper on the capper, as used normally, there is no rib off in the sensible filling area. Along the complete path of feeding, there is the optional possibility to treat the oriented caps. Depending on the needs of the customer systems with UV or chemical disinfection (alcoholic base / peracetic acid / chlorides) or jetting with sterile air / sterile water can be used. Following the highly innovative principle of DynaSort, these orienting elevators offer now a solution for making the heights of the carriers variable by one central wheel. For the fist time one unit for different caps could be realized. The changing of format parts becomes obsolete, when changing caps adjustment is reduced to just a few seconds.
This hygienic design, including a maintenance free chain of plastic and stainless steel, follows the wishes of beverage industry very closely. DynaSort are available for normal and high speeds of bottling lines. Fully integrated into the large Gassner standard program of Cap Feeding- and Transportation Systems complete solutions can be offered to the needs of the customers.
Orienting Elevator type < DynaSort > for standard screw-caps and Push-Pull (sports cap)
Cap logistics for large bottlers - the Basement cluster
New components for handling a number of different types of cap in use at the same time on several bottling lines are now available from Gassner, the specialist for cap feeding systems. The starting-point is the commonly encountered situation with central storage of all the cap types in one storage area, where the caps are held ready in basements (bins), grouped together in a cluster. Automatic distribution to the individual filling lines, according to requirements, takes place from this central location, using the very latest conveyors and branches. Gassner has a complete range of modern components for this application. Some of the key subsystems have been revised and technical improvements made.
The new multi-track series HB-2 and HB-3 belt conveyors form the backbone of multiple track cap feeding. Up to three tracks run on each of these lines, which are combined into a compact unit, with minimal space requirements and independent drives. Each track supplies a different bottling line. Selective distribution from each individual basement to each line is handled by the new HW model horizontal branches. Unlike systems previously available, these are fully encapsulated and optimised for hygiene.
To ensure a clear view of the logistical structure, even in complex distributing situations, a new control panel is implemented. A touch screen with full graphics display provides see-at-a-glance information about current line status, while simple, intuitive navigation aids enable even unpractised temporary personnel to operate the system without any problems. For large bottlers, this technology is a very rational way of distributing all the caps from a cluster of 10 to 20 basements to any number of bottling lines.
Specific complete solutions for all cap feed applications are developed for customers and fully integrated into the wide standard range of GASSNER cap feeding systems. From screw caps to crown cork, twist-off caps or other types of cap, supplied in Octabin containers, box pallets or hand boxes, whether handled by magnetic conveyor, bucket conveyor or pneumatic conveyor segment, conventionally or oriented – Gassner always has the right solution.
GASSNER, the specialist for cap feeding systems, completes the offered machinery with an integrated UV germicide.
There are similar systems directly in the transfer conduit to the closer, but the new combination with an orientated feeding system carries out radiation directly on the belt conveyor.
This system has been improved technically by using "cold" UV radiation. As opposed to other systems, hardly any energy is changed into heat; demand for energy and thus operating expenses are very low. Moreover, this is a rugged, long-life and troublefree system because complicated, mechanically locked, protective shutters are not required as thermal shields. The process step is easily accessible and easy to survey and nevertheless does not threaten operators. There is no danger of product contamination because there are no chemical substances. In this way, a reasonable and low-pollution system has been created which, however, is very efficient because a long way on the feeding line is available for radiation.
The UV germicide integrated into the feeding system is intended to complete other methods, e.g. chemical disinfection. If required, other combinations are also possible (in order to reduce concentration of chemical reagents considerably). Customer-related complete solutions for any use of cap feeding are elaborated, perfectly embedded into the large standard program of GASSNER Cap Feeding Systems. GASSNER offers the perfect solution - whether screw caps, crowns, twist-off caps or other caps - whether delivery in octabin containers, skeleton containers or hand boxes - whether using bucket elevators, belt conveyors or pneumatic conveyor segments - whether conventionally or orientated by location.