KRONES Academy

Overview
PET-Asept-L

Author: Daniel Winkler

Date: 21.02.2020
2 ｜KRONES Academy – PET-Asept L

Aseptic: all process steps at a glance

Treatment Media Product Caps

(e.g. filtration) (UHT process) (hydrogen peroxide steam)

Aseptic filling line

packaging

Packaging Aseptic Aseptic Finished packed

Sterile

(preform or finished filling capping goods

container)

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3 ｜KRONES Academy – PET-Asept L

The design: PET-AseptBloc L with blow moulder

1. Preform feed unit

2. Blow moulder
3. Container steriliser
4. Rinser
5. Cap sterilisation system
6. Capper 4
7. Filler
7 3
2

6
5
1

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4 ｜KRONES Academy – PET-Asept L

The key components: Container steriliser

− Continuous treatment of container exterior with a

mixture of peracetic acid and steam
− Spreader-shaped nozzles for thorough cleaning of the
neck area
− Best draining properties by Tabletec table top inclined to
one side
− No use of surfactants

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5 ｜KRONES Academy – PET-Asept L

The key components: Rinser

− Removes residual peracetic acid from the containers

− Efficient single-channel full cone nozzle with adjusted
dimensions
 Without CIP cups
 Open SIP in the clean room housing
− Reduced water consumption
− Time saved during rinsing and cleaning
− Recycling of the peracetic acid
− Recycling of sterile water

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6 ｜KRONES Academy – PET-Asept L

The key components: aseptic filler

− The product is fed from top via a media distribution system

with axial face seal and integrated condensate barrier.
− Steam sterilisation of the filling valves
− No CIP return required: open CIP in the clean room housing
− Reduced loss of product thanks to product feed from top
− Highest microbiological safety
− Time saved during sterilisation
− Extended maintenance intervals

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7 ｜KRONES Academy – PET-Asept L

The key components: Cap sterilisation module

− Simple mechanical design

− Sterilisation of the caps by means of warm PAA
− Short treatment time
− Treatment true to quantity: last cap for last bottle

Cap inspection unit

Checks caps for
− deformation, ovality
− faultless tear-off ring on caps
− correct orientation

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8 ｜KRONES Academy – PET-Asept L

The key components: Aseptic capper

− Servo motor for each capping head

− All drives are located outside the clean room housing
− Reduction of the mechanical movement within the
clean room housing
− Liquid barrier for isolating the rotating part from the
static part
− Electrical control cabinet positioned outside of the
clean room housing
− Completely newly developed discharge conveyor
prevents risk of recontamination

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9 ｜KRONES Academy – PET-Asept L

Production: Path of PAA

(Rinser)
Steam

(1) ～ 2800 + / - 10 % ppm PAA

(Injector)
PES (2) ～ 1500 + 20% / - 10% ppm
Exterior desinfection

Capper

(3)
DD Discharge conveyor
～1200 + / - 10 % ppm

Liquid water seals

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10 ｜KRONES Academy – PET-Asept L

The peripherals: standard CIP module without tank

The PET-Asept L is equipped with its own CIP module. Special

features: it works completely without CIP buffer tank because the
machine housing of the block also buffers the CIP fluid.

Benefits to you
− Thanks to the fact that no buffer tank is required, about
85 percent of the installation surface and 40 percent of space-
consuming volume can be saved.
− No separate valve manifold is required for the CIP return flow.
− All media are provided just in time.

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11 ｜KRONES Academy – PET-Asept L

Aqua Asept (UHT) Method of Operation

− UHT = Ultra High Temperature

− Production: Process water from the admission tank is pre-heated in the heat exchanger (recuperator) by hot sterile water, which is
simultaneously cooled. The process water is then heated to the sterilisation temperature in the heater and is maintained at this
temperature for a specific period of time in the heat retainer. After being in the heat retainer, the sterile water is cooled, and
depending on the design of the UHT system, it is stored in the buffer tank, or used.

− Sterilisation: This step is used to sterilise the UHT system and/or additional machines. After being in the heat retainer, the sterile
water is circulated through the heater and heat exchanger via the sterile water closed loop until it reaches the required temperature.
The next machines are also included in the sterilisation process.

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12 ｜KRONES Academy – PET-Asept L

Aqua Asept: Main units

Heat retention Heat exchanger
(+WT)

Heater(+WT) Pre-run tank (+VL)

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13 ｜KRONES Academy – PET-Asept L

Configuration data:
AquaAsept – Sterile water UHT
 Product: defined processed sterile water
 Output: 5 up to 12 m³/h
 Heat recovery: 91 %, Plate Heat Exchanger
 Pasteurisation temperature: 135°C
 Heat retention time: 60 sec.
 Tasks:
- flushing of the filler during grade
change or at the end of production
- Rinsing water , cooling down the
product pipes
- Screw thread spraying system
- Lubrication immersion blank
 CIP supply:
- by Concentrates via concentrates
- internal
 Control:
managed by PCS, connection to LDS

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14 ｜KRONES Academy – PET-Asept L

AquaAsept – Sterile water UHT

Buffer Steam
tank supply
heater

Heat
retention

Process water Heat

supply exchanger

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15 ｜KRONES Academy – PET-Asept L

Tasks AquaAsept
media supply
flushing of the filler during grade
change or at the end of /water looks
production
Rinsing water , cooling down the
product pipes
Screw thread spraying system
Lubrication immersion blank

Sterile water supply via ring pipe

krones AquaAsept D
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16 ｜KRONES Academy – PET-Asept L

Production: Sterile water circle via ring pipe

Injector
Sterile water

Rinser

Transfer valve manifold

Filler

Capper

UHT

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17 ｜KRONES Academy – PET-Asept L

Q520: Sterile product transfer from

sterile tank to the filler

Q520: both valve seat open together

Q521, 522: upper and lower valve seat open
seperate

Upper/lower vlave seat Steam valve

Pipe to the filler

Drain valve
Pipe from FLP

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18 ｜KRONES Academy – PET-Asept L

During running production both valve seat are open (connected pipes) (Q520)

Product to filler

Steam barrier not active

Valve closed

Product from sterile tank

Valve closed

At interruptions during production both valve seat get closed

Steam barrier activ

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19 ｜KRONES Academy – PET-Asept L

Cleaning of filler an isolator (CIP, COP) at the same time in a closed circle

Hot caustic, acid, hot water, cold

water from CIP module

Media in a circle back to CIP module

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20 ｜KRONES Academy – PET-Asept L

Cleaning: CIP / COP

Injector

CIP return
FLP Rinser

Transfer valve manifold

Filler
CIP

Spray nozzles
UHT
z.B. Caustic for COP

Drain piping
COP return

CIP-
module

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21 ｜KRONES Academy – PET-Asept L

Q520: Independend cleaning (CIP) of filler and product treatment

Q520 closed during CIP, filler-circle complete seperated to the FLP-circle

CIP-circle FLP: from

to CIP-plant, FLP
sterile tank, FLP

CIP-circle filler: from CIP-

module or CIP-plant To filler

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 22 ｜KRONES Academy – PET-Asept L

Q521, 522: upper and lower valve seat open alternately and in an interval mode

Upper valve seat opens in intervals, flushes into the open

Dokumentname.pptx / 11.2015

Lower valve seat opens in itervals, flushes into the open

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 23 ｜KRONES Academy – PET-Asept L

Sterilization of filler and isolator (SIP, SOP) successively

First sterilization of the filler with

steam

Then sterilizing the isolater with PAA

Dokumentname.pptx / 11.2015

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24 ｜KRONES Academy – PET-Asept L

Basic for thermal procedures for sterilising

 Pasteurisation: < 100 °C

 Flash pasteurising: 70-95 °C / 30-60 sec.

 Sterilisation: > 100 °C / 1,200-2,400 sec.

 Ultra high temperature treatment (UHT): 135-150 °C

/ 1-10 sec.

Aim Elimination of yeasts,

lactobacilli and moulds

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25 ｜KRONES Academy – PET-Asept L

Thermal product treatment

Optimal planning of the thermal product treatment will result

in a reduced
− thermal impact acting on the product due to the short
dwell times.
− requirement for thermal and pump energy.
− product loss due to reduced line volumes.
− oxidation rate if a VarioSpin product deaerator is used.

Micro-organism
The heating temperatures and periods are defined by the
killing kinetic of the various micro-organisms. An optimum
design of the heat exchanger surfaces can reduce the dwell
time in the heating and cooling zones. It is essential to find
the correct balance between the least possible number of
tubular modules (optimisation of the heat exchanger surface)
and gentle product heating.

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26 ｜KRONES Academy – PET-Asept L

VarioAsept - Modular design of the components

Aseptic buffer tank

Vacuum-sealed and pressurised up to 6 bar
− Maximum safety due to a fully aseptic and
automatically operated valve manifold
between UHT system and buffer tank and
due to an integrated sterile gas filtration
system

Homogeniser
Homogenisation technology of HST
Media supply module
Pressure supply tank (balancing tank) Product heat exchanger
− Decoupling of the downstream process for In tubular heat exchanger or plate heat
stable sterilisation conditions exchanger design, depending on the
requirements
Product deaerator
KRONES VarioSpin Service module
− Product deaeration with patented swirl Energy supply for product heat exchanger
nozzle design − Electrical and pneumatic controller with
MCC and KRONES HMI

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27 ｜KRONES Academy – PET-Asept L

VarioAsept - Deaerator - overall view

6
1. Level regulation valve, 6 Product infeed (Swirl) 2
product feed
7 Deaeration tank
7
2. Flavouring recovery
8 Tank discharge
3. Vacuum control valve 1
9 Vacuum pump
4. Pneumatic cabinet
8
10 Additional pump (optional, 3
5. Product pump, pressure- here positive-displacement
controlled pump for pulp/pieces)
4

10 9 5
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28 ｜KRONES Academy – PET-Asept L

VarioAsept - Deaerator - Tank a

2 b
1 Product feed
1
2 Deaeration tank

3 Product discharge

4 Pressure difference
measurement a The Swirl insert causes a rotary
product motion against the inner

5 Fill level, product discharge

6 tank wall
5
b Aspiration of the gas for
6 Sight glass with light flavouring recovery
4
3

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29 ｜KRONES Academy – PET-Asept L

VarioAsept - Deaerator – Flavouring recovery 6

2

1 Tubular heat exchanger module 4 Vacuum pump connection

(condensor)
5
5 Coolant return
2 Coolant pre-run

6 Deaeration tank connection

3 Drain pipe
1
7 Flavouring recovery
7
4

3
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30 ｜KRONES Academy – PET-Asept L

VarioAsept - Deaerator – Vacuum-assisted deaeration

1 Connection to condenser 1 2
2 Pressure sensor for vacuum limiter
4
3 CIP pipe 5
6 Limited, because depending
4 Regulation valve, vacuum limiter
on the product temperature
(boiling) and foam behaviour
5 Sealing water tank 3 of the product

6 Temperature sensor

7 Vacuum pump
7

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31 ｜KRONES Academy – PET-Asept L

VarioAsept - Benefits to you

Temperature control by choice Aseptic product change-over

The heating process can be optionally controlled with a Water flushing within 35 minutes between the last and the first
precise F-value or temperature control system, or through bottle (for KRONES standard layout) provides high flexibility for
flexible PU regulation. production.

Long production times Gentle product treatment

Aseptic intermediate cleaning with caustic at the product The thermal and oxidative stress on your product will be reduced
treatment temperature of the heat exchanger can be carried because specially designed inner tubes in the selective heater and
out without interrupting the aseptic filler production as the chiller sections can be heated and chilled again very quickly.
filler is supplied by the aseptic buffer tank.

Low product losses

A rework tank for mixing phases, the integrated buffer tank
and automatic output regulation in the event of production
fluctuations in upstream and downstream systems contribute
to high cost effectiveness.

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32 ｜KRONES Academy – PET-Asept L

VarioAsept - Product

Injector
FLP

Rinser

Transver valve manifold

Product Filler

Capper

 KRONES AG 2019 - No utilisation, copying and/or distribution without author's consent.