As we all know, during the traditional production process of bottled water, finished water is mixed with ozone to form ozone water in certain concentration degree before filling. This craft can be easily operated, with highly efficient non-residual sterilization, and has relatively lower requirement of filling environment, the sanitation of bottles and caps and other packaging materials. So this kind of ozone sterilization filling technologies is widely applied. But due to the fact that the ozone may affect the flavor because of the reaction between ozone and mineral elements, what’s worse is that the health friendly bromide will mutate to bromate under the influence of ozone, and when the bromate exceeds some certain degree, it may cause health hazard and the probability of cancer.
Nowadays, many countries list the bromate into the strictly controlled hazardous substance in the security inspection. This is also emphasized in the new standards of Portable Natural Mineral Water regulation. With higher living standard and vaster popularization of scientific comment sense, customers pay more and more attention on the safety of portable water. New ozone free mineral water processing technology certainly will be the new tendency of this industry. As the expert and leader of the China’s high-end liquid (beverage) packaging machineries industry, Newamstar shoulders the inevitable responsibility, to conquer the key technical barriers of ozone free mineral water, and provide a guarantee of equipment and a support of crafts.
First of all, let’s check the risks we’re facing during the ozone free mineral water process.
- Microbe Risk of Product Water.
Ozone free means the lack of ozone’s sustainable sterilization effect on filling process. So without ozone, to eliminate the outcome caused by pathogenic bacterium and other microbes is becoming a new problem.
- Microbe Risk of Packaging Materials (bottles and caps)
Since during the traditional ozone filling process, the filled bottled water still possesses sustainable sterilization ability, coming from ozone, so the primary sterilization requirement is relatively lower. However, in the section of ozone free filling, it’s essential to reinforce the sterilization of the packaging materials to control the microbe index of product water conveniently.
- Microbe Risk of Production Environment.
During traditional ozone mineral filling process, normally for filling environment, the one thousand grades purification would be sufficient. As for ozone free one, the filling devices will be exposed in the average one thousand grades purification environment, while the microbe, carried by the staff of maintenance, tools and components, will flood in.
Secondly, to eliminate the potential risks, what technologies are applied during filling process?
- Water treatment must utilizeair isolation, CIP and SIP technologies.
The resources of natural mineral water are always locating in the mountainous area, forests or in the wildness, with very little pollution and are relatively purer. But some water intakes are nearby the earth, stratums, plants and other complicated air environment, which impose bad influences on the sprung mineral water, especially the microbe pollution. So in the whole water treatment design, beside the protection of water resources, all the links between water intakes, transportation, storage and filtration shall be specifically designed with the reference of the resource environment and quality.
Water treatment must apply sir isolation technology. The system should be sealed reliably during the whole process, in avoid of the influence on water quality caused by the microbe brought from the contact with the surrounding air. So a sufficient level of air filtration should be put into use in the parts that will inevitably contact with air for isolation. For example, the storage tank is internally equipped with respirator with sophisticated filtration. And the correspondent links shall be installed with complete CIP and SIP sterilization system.
- Sterilization of Packaging Materials.
(1) Ion Electrostatic Dust Removal Technology.
The transportation, storage and usage of pre-forma and caps may easily cause static, which draws the attachment of dust. While dust is the incubator of various microbes, it may pollute the packaging materials easily. The new type of Ion Electrostatic Dust Removal Technology can remove dust on pre-forma and caps of bottles. This technology not only is energy efficient, but also saves a large amount of sanitizer and water, which are essential for traditional washing technology.
(2) UV ultraviolet ray sterilization of pre-forma and caps.
(3) H2O2 VHP Spraying Sterilization Technology.
H2O2 is now widely used on medical science as a safe and efficient sanitizer, which is also beginning to show its function in beverage packaging field. This technology sprays the evaporated H2O2 essence onto the surfaces of pre-forma and caps of bottles, and sustains its highly effective sterilization to pre-forma and caps during the high valid activity time. Comparing with the traditional spraying sterilization technologies, it saves a large amount of sanitizer, water, energy and land in use, also simplifies the devices and operation.
(4) Sterilization Oven with IR infrared rays and UV ultraviolet rays integrated
IR infrared rays heater heats the pre-forma up to 100-120℃, because the high temperature has some certain ability to sterilize microbes, which, at the mean time, gives the best activated warm zone for the evaporated H2O2, saving extra energy during the process. In this way, the traditional infrared heating oven is becoming a sterilization oven for the evaporated H2O2. Moreover, in the pre-forma heater, except for the IR infrared light boxes, UV ultraviolet light boxes are added to sterilize the spiral part of the pre-forma, which passes the lower temperature section. This ensures a more thorough and reliable sterilization of pre-forma.
(5) The 0.01μm high accuracy blowing air filtration can block various bacterium and mucedine.
The blowing machine’s high-pressured air goes through 0.01μm aseptic filtration to ensure the air won’t bring the microbe into the bottles.
- The controllingtechnologyof the equipment environment.
(1) double environmental purification technology.
The blowing, filling and capping devices are placed in the exterior 10-thousand grade workroom. The build-in filling purification devices can double the purification to ensure the core section filled with aseptic air, which can reach the 10-thousand grade.
（2）positive pressure section’s technology in empty bottles transit area
FFU units are attached above the transit area between the pre-forma in the blowing machine and empty bottles. And the positive pressure cleaning area is formed by the U15 graded HEPA high efficient filtration, to avoid the microbe of the surrounding are falling into the pre-forma and empty bottles.
The positive pressure intensified air section, set in the transition area from the blowing machine to filling machine, also uses the U15 graded HEPA high efficient filtration to form a positive pressured aseptic isolation air seal, which effectively separate the air of dry area from the humid one.
Above all, using the traditional bottled mineral water production line with sterilization ability of LOG3 to undergo the ozone-free mineral water production exits many risks. And to use the one with the ability of LOG5 is way too expensive. So on the basis of the traditional production equipment with sterilization ability of LOG3, we add up all the above mentioned new technologies, in which way, the ozone free mineral water filling equipment with LOG4 sterilization ability can be created. And this may become another reliable and economic alternative resolution for the ozone free mineral water production.
We believe that with the nirvana of mineral water’s filling technology, the fresh and innovative ozone free filling technology will welcome its vibrancy and bring the customers healthier and more natural mineral water, and the reassuring nutrition for life.
NEWAMSTAR HIGH-SPEED BLOWING-FILLING-CAPPING COMBIBLOCK
Newamstar High-speed Blowing-filling-capping Combiblock combines the blowing system, filling system and capping system in one integrated system, reducing several intermediaries suchas transmission, empty bottle handling and storage processes, which improves packaging hygienic condition and reduces packaging ross-contamination so as to improve the overall operating efficiencybut lower the energy consumption, thereby reduces the overall production cost of enterprises.
- Product Range: Production capacity from 12,000 BPH to 80,000 BPH.
- Applications: It is applied to PET bottled pure water, carbonated soft drink, juice, liquid dairy, liquid condiment and household & personal care products, etc.
Stable infrared ray heating system and independent heat balance device ensure the stable temperature of the preform, even color of the bottle and increase of the output.
Special designed twice-blowing system can monitor the pressure in each mold in order to provide accurate real-time parameter for operator. It is easy for the operator to adjust the parameter and ensure the stability of bottle forming.
High-speed and high-accuracy diaphragm type filling valve: Equip air back channel which is separated from liquid carousel, by which, the air replaced from the PET bottle won’t enter liquid carousel to avoid second pollution. Equip cleaning dummy bottles which can realize online CIP.
Sanitary and washable capper：Optimized cam surface design ensures the minimum
impact force of the capper .Bottle discharging starwheel is screwing decently, so it is unnecessary to adjust the conveyor height during bottle format change.
Driven by innovation and win the market by quality!
Newamstar has focused on liquid packaging industry since from its establishment. Taking innovation as guide and basis, we have been forging ahead constantly.
As an outstanding company in China high-end equipment industry, Newamstar has built a dimensional product system gradually including beverage, milk, alcohol, condiment and daily used chemicals. We have won many innovative “China First” for various products. All these achievements and milestones will be fixed and memorized in the long history of Newamstar.
INTELLIGENT STEREOSCOPIC WAREHOUSE SYSTEM: THE FIRST CHOICE OF BEVERAGE FACTORY TO UPGRADE THE MODERN WAREHOUSING AND LOGISTICS!
In recent years, with the increasing of automation and production capacity of liquid food packing line, contradictions between inventory and production capacity have become increasingly prominent. At the same time, with the increase of land cost and labor cost,traditional discrete model of warehousing and logistics using single logistics equipment or personnel to carry out the transportation of product and raw materials has been outdated.
With the deepening of “industry 4.0” and “Internet +” concept, the Chinese industry is transforming from the traditional labor-intensive to the industrial automation, and the traditional management mode based on people is turning to computer-based Information and modern management. Intelligent equipment represented by robot and a new generation oflogistics model with the function of data collection, management and data tracing is being more widely used in the market.
As the Chinese leader in the field of liquid packaging, Newamstar accumulated rich experience in long-term development. By industry research, product technology development and the integration of industry resources over one year, Newamstar introduced the concept of “Internet +” into the production line followed by the pace of “Industry 4.0”. On the basis of rising the capacity and stability of liquid packaging production line, Newamstaroptimized the structure of production lines and improved the level of automation of the production line by reducing the cost, and improving the quality and efficiency.
- Goods transition and storage – high rise shelf, tray and container.
- Check in & out device – palletizer.
- Check in & out distribution system – roller and chain conveyor, distributing vehicle, lifter, etc.
- WCS control system – includes check in-out device controlled by computer, distribution system, various kinds of inspection and safety device controlled by electricity.
- WMS warehouse management system – warehouse account management, data analyzing, goods site arrangement, device operation and warehouse storage display, etc.
A double extension tunnel stacking machine is adopted in the projects of“Moon over a Fountain Co. Ltd”, which achieve an effective balance between capacity and efficiency by improving space utilization and flexibility of warehousing in a limited space. The production line is connected with the warehouse directly, so a lot of material transfer links was saved. With advance internet technology, it realizes the resources and data sharing and connection between the ERP(enterprise resource management system), MES (manufacturing execution system) and WMS (warehouse management system) to reduce the mistakes and speed up access of the goods. Compared with the traditional discrete warehouse, Intelligent stereoscopic warehouse system can save the cost of land investment, reduce labor intensity, improve the working environment and reduce labor costs, finally improve the production efficiency and the level of modern management by making packaging and storage systemIntegrated, automated and intelligent.
In 2015, with excellent R&D design team and processing advantages of equipment manufacturing, Newamstar completed the development of automated warehouse system with tunnel stackerand RGV rail transport trolley. In the same year, Newamstar successfully presented it on CBST exhibition in Shanghai, and received wide attention from lots of companies in the industry. In 2016, automated material transport under special circumstances is solved by researching and developing non-rail AGV transport trolley. Through the introduction of advanced visual logistics simulation software FlexSimand excellent simulation designers, we can make simulation test in the project planning process, and do all kinds of system analysis and engineering verification for the model to get the final optimized the design. It can also quickly confirm the logistic equipment solution, further verify the feasibility of the project, provide improving and management basic data for the system, and reduce operating costs of production enterprises.
Currently, Newamstar are upgrading internal logistic systembased on stereoscopic warehouse system, will build automated logistics system by using AGV non-rail Intelligent trolley to distribute the raw materials, and create a new automated management system with the product lifecycle management, process management and information management.
New age, a new chapter, a new dream. With the evolution and promotion of intelligent stereoscopic warehouse system, it will help beverage manufacturers to clarify and refine requirements, quantify data target and accuracy control of the production process, and finally help to realize the intelligent, automation and modernization of plant.