Beverage manufacturers can now benefit from aseptic technology for smaller production runs following the launch of a new low-output integrated aseptic blow-fill-cap solution from Sidel. Introduced in response to market demand, this new Sidel low-output aseptic Combi Predis™/Capdis™ FMa is based on the dry-preform and cap decontamination technology already successfully implemented and proven by major names in beverage manufacture throughout the world.
With a standard output of 12,000 bottles per hour (bph) for a 1L bottle, the new low-output solution can accommodate high- and low-acid products packaged in all common bottle volumes required by the market - between 0.2L and 2L, with outputs of up to 16,000 bph. It brings a new dimension to Sidel's range of aseptic Combi Predis/Capdis FMa solutions, which, with capacities of up to 48,000 bph, has set the new aseptic standard for the beverage and dairy industries.
Market drivers for the new launch
Greater potential in low-output aseptic production is an increasing requirement worldwide, particularly in regions like Europe, Central and South America. As consumer tastes mature, the product portfolio from beverage manufacturers has developed. Increasingly innovative recipes and flavours such as aloe vera or soja milk have been adopted; new textures, including the introduction of fruit pieces, are more common; and there is also the wider functionality role of beverages, particularly in terms of the expanding market for health drinks.
Prior to a wide-scale roll-out, beverage manufacturers often produce these products in small batches in order to market-test them and gauge consumer reactions before moving towards large-scale production. These sophisticated products, positioned in niche markets, must be produced on slower-moving lines. Low-output production can also be a practical solution in regional markets which require smaller product volumes.
In the dairy industry, low-output packaging solutions are common, particularly in UHT milk production. This new low-output aseptic Combi Predis/Capdis FMa offers competitive PET packaging solutions for this market. It also creates potential differentiation through innovative packaging while providing the capability to easily handle different shapes and formats.
Based on proven dry-preform and cap decontamination technology
The new low-output version is based on the worldwide success of Sidel's dry-preform and cap-decontamination system - Predis and Capdis - which enables the sterilisation of all types of preforms and caps within an integrated blow-fill-cap solution. This cost-effective version offers significant environmental benefits. It provides 100% decontamination of the bottles and caps without the need for water and with very little chemicals by employing hydrogen peroxide mist. Traditional aseptic filling systems that require bottle rinsing consume approximately100 cubic metresof water and170 litresof chemicals per day for this specific kind of low-speed operation. It also reduces electrical consumption by up to 45% from the Ecoven compared with Sidel's previous generation of blowing solutions, all while ensuring excellent material distribution and bottle quality.
The whole aseptic Combi equipped with dry-preform and cap decontamination cuts annual costs by up to 30% compared to dry bottle decontamination.
Dry-preform-decontamination technology improves food safety. It helps to protect liquid packaging from microorganisms, preserves the integrity of sensitive drink products and lengthens their shelf life, while keeping the taste natural and pure. It is ideal for handling products for ambient distribution (room temperature) and it can even extend products' shelf life when distributed in the cold chain (refrigerated distribution). It can also contribute to reformulate naturally sensitive products that were traditionally packaged with preservatives.
Compact and linear footprint
Attention has specifically been paid in the design of the low-output Combi Predis/Capdis FMa to accommodating it easily into new or existing plants through its ultra-compact footprint (up to 30% reduction in the footprint compared with existing linear solutions). Its linear design also allows for parallel packaging machines, a typical layout in the milk industry.
With its special 'plug and play' conception, on-site installation is simpler and faster and can be managed in 'hidden time' while installing the rest of the line. Despite its compact design, the platform remains ergonomic and straightforward. Excellent accessibility to the machine's key components has been ensured, allowing operators to maintain and manage it easily.
Flexibility with maximum uptime
Because bottles are blown from decontaminated preforms and the empty bottle does not endure any thermal stress, the Combi Predis/Capdis FMa system provides total freedom of bottle design. This means beverage producers can realise almost any type of intricate bottle shape, whether round or square, small or large, in many different sizes, mainly from 0.2L to 2L. Due to continuous by-the-neck transfers and the absence of thermal stress, there is no limit in terms of bottle light-weighting. Beverage producers can easily customise their bottles with a large range of caps, whether flat or sport caps. The Combi Predis/Capdis FMa offers all the advantages associated with PET bottles, and, particularly, the rigidity of the PET bottle neck combined with caps specifically designed for aseptic packaging. This provides full tightness against microorganisms and therefore excellent food safety of the product, even for UHT milk. This means there is no longer a need for the use of aluminium foil, while also offering all the benefits of the dry caps decontamination Capdis. As a result, the flexibility in production is complemented by economic and sustainability advantages.
Predis and Capdis are extremely simple to operate. The aseptic low output Combi Predis/Capdis FMa maintains a completely aseptic filling environment without any need for cleaning for a non-stop production of up to 120 hours. Only a three-hour cleaning and sterilization time is required between two bottle-to-bottle productions. This solution is also proven to deliver quick and easy format and liquid changeovers. With the latest innovations implemented on the low-output version, no operations are required for format changeover in the aseptic zone, which means no loss of sterility and reduced downtime on the line. The time required for product and cap changeovers is also reduced to a minimum, particularly given that in some cases there are no parts to change when it comes to product, shape or cap changeover. Finally, this aseptic low output Combi Predis/Capdis FMa can be supplied with aseptic injection of liquid or gas nitrogen before capping, in order to pressure packaging or protect products sensitive to oxygen.
"This is the best solution to meet today's growing demand for low-output innovation for juices, nectars, teas and also liquid dairy products, including UHT milk," explainsGuillaume Rolland, Aseptic Product Manager. "It leverages our unrivalled innovation in aseptic dry-preform and cap technology, maintaining beverage quality and protecting liquid packaging from microorganisms."
