JBT AsepTec: Linear Aseptic Filler
JBT SF&DS' experience and expertise from our 2nd generation aseptic filler (which was the first low-acid filler for plastic bottles to receive a letter of non-objection from the FDA in the USA) has been incorporated into the design. Open type HDPE bottles are sterilised in the filler prior to entering the aseptic zone where filling and sealing with PE-coated aluminium foil closure or aseptic screw cap occur.
Other features include low energy consumption and the possibility to change between different container shapes and sizes and even products without interrupting the packaging process for a sterilisation cycle. The advanced user-friendly control system with touchscreen HMI has automated programmes for production, cleaning and sterilisation. Full access is provided to the complete process and production history of every individual bottle that left the filler. Capacity: up to 24.000 bottles per hour.
The JBT AsepTec® is unique linear aseptic filler. It stands out by the range of products and bottles (HDPE, PP, PET) it can handle, its high speed, its reliability, and its flexibility. It was designed from the ground up to provide carefully controlled and verifiable filling conditions and to meet the strict requirements of the validation-by-design concept. By identifying the factors, which reduce the reliability and sterile conditions of conventional fillers, we could avoid them in our new design, thus creating a new generation of fillers.
JBT AsepTec units can handle high and low viscosity products and even products containing solids, so a single filler can handle your full product range. The technological performance of the JBT AsepTec is just one of the characteristics which makes it so unique.
Efficiency and Reliability
You expect your investment to generate revenue for your company. Maximizing your revenue means minimizing downtime. Hence JBT AsepTec fillers have been designed from the ground up for the highest reliability. JBT's engineers painstakingly analyzed all failure modes and took steps to eliminate them. All of the desired settings can be performed while the machine is in operation, without interfering with the sterile conditions.
Furthermore, the smart split scroll bottle feeder design means you can bypass a problem in one filling lane, while the other lanes continue the production run. This means you can finish the run, without interruptions for repairs or sterilization. Together, these features enable you to have long production runs and you may even be able to change over to a different product or container without needing a sterilization cycle.
Unique air management system
The combination of a very small aseptic zone and the special air distribution system is the most important innovation in the JBT AsepTec. The principle is based on a unique combination of overpressure and downward flow force. The aseptic zone overpressure prevents non-sterile air from penetrating the aseptic zone. The laminar down flow keeps the area sterile and carries off possible contamination. This is quite different from cross airflow systems where air passes many bottles before leaving the system.
The JBT AsepTec's air management system prevents recontamination of the bottles without the need to create an active environment in the entire machine. Renewing the air volume several times per minute in the aseptic zone safeguards the sterile conditions.
Another advantage of this design is that it uses low-pressure air supplied by fans and HEPA filters, rather than high-pressure air. The air management system not only ensures sterility but also maintains a constant temperature to prevent product drying on the filling valves. When products are filled at a low temperature the air can be dried to prevent condensation on the bottles.
Obviously the main challenge with equipment of this type is to maintain the required conditions in the aseptic zone. For this reason we have minimized the size of this zone and the number of mechanical components in it.
JBT AsepTec fillers use hydrogen peroxide to decontaminate the bottles. The precisely engineered system ensures effective sterilisation with a minimum peroxide consumption, while meeting the most stringent requirements as to residual peroxide level. The fillers can process open bottles, which need to be sterilised internally and around the neck, and aseptically blown closed bottles, where only the neck is sterilised and then trimmed to open the bottle.
The art of filling
The JBT AsepTec fillers are based on flow meter technology for a high accuracy (and thus minimum give-away) and impressive reliability. The flow meters and valves are located outside the aseptic area to minimize the size of the area where sterility needs to be maintained. The filling process can be divided into two stages to combine high speed with high accuracy.
The filler nozzles are based on the proven Dolphin design and can handle products containing fibers or small particles without dripping. Dedicated nozzles are available for products containing larger solids. This allows you to process a wide range of products with a single unit.
A modular design to meet your current and future requirements.
JBT AsepTec fillers have a modular design. Many of the JBT AsepTec supplied are designed with a spare position as a preparation for later modification or expansion of the system. This option makes it easy to modify them to suit changing requirements. The modularity ensures that your filler meets not only your current, but also your future business needs.
We have a range of optional modules amongst others for trimming closed bottles, additional filling steps, nitrogen purging and processing screw caps. Each of these units integrates fully with the main JBT AsepTec computer control system.