Key process optimization and intelligent filling solutions for the integrated blowing, filling and capping system

During work, the small bottle is blown into an empty bottle by the bottle blowing machine and transmitted to the filling machine through the manipulator and transition wheel. Since the working environment of the filling machine and the bottle blowing machine is completely different, they interfere with each other. During filling, the wet area requires a lower working temperature. However, bottle blowing requires a dry environment and is a heat source area. This requires considering effectively separating the bottle blowing machine from the filling machine, setting up a transition cabin, leaving only the gap for the bottle in and out in the area, and making it as closed as possible. The top FFU clean positive pressure airflow, cuts off the air, and can prevent water vapor and hot air from flowing into each other.

Of course, after the empty bottle comes out of the transition cabin area, it is transmitted to the filling host through several transition wheels. During this period, we must perform necessary cooling treatment on the bottom of the bottle to ensure the subsequent filling quality.

The temperature of the bottle coming out of the bottle blowing machine is relatively high. When filling carbonated beverages, the material liquid temperature is low and the carbon dioxide is extremely unstable after mixing. The temperature of the bottle bottom must be reduced from 60~70℃ to 40~50℃ to avoid the heat of the bottle body affecting the filling material and causing foaming. A certain number of spray cooling nozzles are configured below the filling transfer star wheel from the bottle blowing to the filling transfer star wheel, and the bottle bottom is cooled by spraying external water. The number of nozzles depends on the filling speed and the bottle combination arrangement. After experimental verification, the cooling time takes 5 seconds to achieve the effect. The actual cooling interval is designed to be no less than 8 seconds so that bottles with different bottom weights and shapes can be processed. In the nozzle design, a large cooling surface is guaranteed, and high-efficiency spray nozzle cooling is used to greatly reduce water consumption. In addition, cooling water circulation can be performed according to customer selection, which is more energy-saving and emission-reducing.

When the cooled empty bottle is transferred into the filling host, the filling valve is ready to start working. As the most important core component of the filling machine, we will give priority to recommending electromagnetic flowmeter electronic valves to customers. The traditional mechanical isobaric filling valve and electromagnetic flowmeter electronic isobaric filling valve are basically similar in filling process. The difference is that the mechanical valve uses an actuator to realize various filling process actions according to the installation position, while the electronic valve is automatically controlled according to the time sequence through an electrical program. In this way, even when the equipment running speed changes, the filling of the electronic valve can still automatically execute the set action time to meet the constant filling state, ensuring the quality and accuracy of the filling. Compared with the mechanical type, the electronic valve relies on precise control and reliable execution to better meet the requirements of high quality, high efficiency, low consumption and intensive design. Today, the structure and function of the newly developed filling valve of Newamstar have made major breakthroughs.

The lifting cylinder and the valve are designed as one. The structure is simple and easy to clean. The structure without a separate lifting cylinder reduces maintenance costs and enhances equipment reliability. Moreover, in addition to carbonated beverages, the valve is also suitable for the filling of mineral water and fruit juice drinks.

The valve can also select the filling mode according to the material, and can adopt the method of slow first, fast later, and slow last, which is convenient for controlling accuracy, conducive to the stable filling of materials, and prevents foaming. It can also increase the filling temperature, realize the normal temperature filling of carbonated beverages, and save energy consumption.

The electronic valve is designed with a unique spiral feeding filling valve method. The filling material is evenly filled along the bottle wall, which is conducive to controlling the CO₂ mixed in the material, ensuring a gentle filling process with less foaming, and is particularly suitable for carbonated beverages that are prone to bubbles and high in temperature. In addition, the valve cavity backwashing function is bypassed during cleaning to increase the path of the cleaning channel, solving the problem that it is difficult for the small exhaust cavity to form a CIP cleaning flushing force, and enhancing the cleaning effect. Each filling head is equipped with a cleaning cup, and customers can choose manual or automatic cleaning cup installation methods according to their needs.

To further ensure the filling quality, the feeding, standby pressure, and exhaust of the filling host are all PID-regulated, and the control and filling are stable, especially the exhaust cavity is concentrated and maintained, which is conducive to controlling the stability of exhaust, and is particularly suitable for carbonated beverages with higher temperatures.

After the bottle is filled, it is transmitted to the capping machine through the dial wheel. The design of the capping machine is suitable for different bottle caps. According to the needs of carbonated bottle caps or drinking water bottle caps, the top differential DC motor can be directly adjusted on the touch screen to accurately adjust the number of capping circles for different bottle caps. Of course, in addition to the conventional disinfectant spraying, the bottle cap processing method can also be configured with a medium-pressure ultraviolet sterilization device or an ion gas purge device on the cap drop guide rail according to the customer's configuration requirements to meet the customer's diversified bottle cap processing needs.

In actual production, people often need to change various types of beverage bottles on a line according to market conditions, ranging from 250ML to 2.5L beverage bottles. Therefore, it is necessary to adopt a quick-change structure. The new change part quick-change structure can shorten the working time by nearly half, greatly improving production efficiency.

In addition, the large-scale use of solenoid valves and diaphragm valves puts higher requirements on the level of electromechanical matching. The integrated integrated control system and newamstar online detection system comprehensively apply light, machinery, electricity, gas, liquid, etc., integrate integrated integration and image recognition technology, and use servo systems for synchronous control, so as to realize the integrated control and production of multiple unit equipment, meet the production needs of multiple beverages at the same time, and achieve the purpose of one machine for multiple uses, so as to realize the scientific layout of the production line, seamless docking and integrated control, reduce investment costs, reduce energy consumption and reduce equipment maintenance costs. Integrated production capacity. The English name of the electronic filling valve blowing, filling and capping machine is (Blowing-Filling-Capping Combiblock -Newamstar)/(Blowing-Filling-Capping Combi Block -Newamstar). Compared with the traditional filling method, it has incomparable advantages in key indicators such as energy saving and emission reduction, filling accuracy and reliability, and has broad prospects in the future.