What is aseptic filling machine?
The role of the aseptic filling machine
is to be sterilized food (dairy products, etc.) packaged in an aseptic environment
, and closed in a sterilized container in order to achieve a longer shelf life in the absence of preservatives, without refrigeration conditions.Aseptic filling equipment
is directly connected with the sterilizer, which can fill the products directly into the aseptic bag after UHT sterilization. The aseptic bag is an aluminum-plastic composite multi-layer bag, which can effectively isolate sunlight and oxygen; maximize the guarantee of product quality.Aseptic filling line
can fill different kinds of aseptic bags or aseptic boxes from 1L to 1300L. The products can be stored for more than one year at room temperature, which can save the cost and risk of low-temperature refrigerated transportation.
Working principle of aseptic filling machine
Aseptic filling machine is one of the widely used filling types of equipment in food, pharmaceutical, cosmetic and other industries at present. Aseptic liquid filling machine is mainly used for filling liquid and semi-fluid products, the working principle is as follows.
a. The liquid product is transported to the storage tank of the filling machine through the pipeline, and it is heated and sterilized through the pre-treatment method, which makes the liquid in the storage tank become aseptic.
b. Using the filling head technology of the aseptic packaging machine, the liquid product is quantitatively injected into the bottle or box, and at the same time, the screwing and sealing of the bottle or box lid can be automatically completed.
c. Through the discharging pipe, the products that have been filled are transported to the packing area to complete the whole aseptic filling process.
With the features of high efficiency, safety, and hygiene, aseptic liquid filling machines can realize fast, accurate, and stable, aseptic filling and sealing of liquid and semi-fluid products. This equipment can not only reduce manual operation time and production cost but also ensure the quality and safety of the products to meet the user's production needs.
Sterilization of aseptic filling machines
Heat sterilization method is a common aseptic filling machine sterilization method, which uses high temperature to kill all microorganisms and ensure that the filler is stored in a sterile state for a long time. Heat sterilization methods according to different filler and packaging materials to choose the heating method and time, generally have the following kinds
|Atmospheric heating||Put the filler into the sealed container, natural heating at room temperature, gradually increase the temperature and keep it for a period of time to kill all the microorganisms in the container.
|High Pressure Heating||Place the sealed container in a high-pressure environment, heating until the temperature reaches the sterilization requirements, maintain a certain period of time after cooling.
|Boiling water sterilization||Put the filler in a sealed bag, boil the water and then immerse the bag in hot water to achieve sterilization.
In aseptic filling systems, heat sterilization method is easy to operate, reliable, will not cause residues on the filler, but for some temperature-sensitive items are not very suitable.
Chemical sterilization is the use of chemicals to kill microorganisms. Commonly used biocides for this method include hydrogen peroxide, ozone, chlorine and chlorine dioxide. This method can kill most of the microorganisms, but the side effects of commonly used drugs is larger, may produce residues on the filler.
Radiation sterilization method is a powerful electromagnetic energy for sterile filling method, which is widely used in bonded warehouses and export enterprises. Radiation sterilization can not only kill microorganisms but also effectively deal with a variety of bacteria that produce toxins and chemical residues, to ensure the absolute safety of aseptic filling.
Working process of aseptic filling machines
Aseptic filling process refers to a series of operational processes for filling drugs under aseptic conditions. Aseptic filling is a very important part of drug production, directly related to the quality and safety of drugs. The following is a detailed introduction to the aseptic filling process.
The workflow of aseptic filling machine mainly includes the following links: preparation, material preparation, equipment preparation, aseptic operation, filling operation, sealing operation and cleaning and disinfection.
Before aseptic filling, the operator needs to prepare the required materials and equipment, prepare the workplace to ensure that the aseptic environment is clean.
Material preparation means preparing the required products and filling containers. Filling containers are also cleaned and sterilized to ensure their sterility.
Equipment preparation refers to the preparation of equipment used for filling, including filling machines, sealing machines, testing equipment, and so on. This kind of equipment should be verified and inspected to ensure that it meets the requirements of aseptic filling.
Aseptic operation is the most critical part of the aseptic filling process. Operators should wear sterile clothing and gloves and after hand sterilization. Operate on the aseptic operating table to avoid contamination of the operating environment. Operators should strictly abide by the operating procedures to ensure that the operation process does not produce bacterial contamination.
Filling operation is the process of filling products into sterile containers. The product is filtered and purified and then filled through a filling machine. The filling machine will inject the product into the container in a predetermined dosage and seal it.
The sealing operation seals the filled container to prevent contamination of the product. Sealing can be done by hot sealing, cold sealing, or other sealing methods. The operator should ensure the quality and integrity of the seal.
Cleaning and sterilization
Cleaning and sterilizing is the last part of the aseptic filling process. Operators should clean and sterilize the used equipment and workplace to ensure a clean aseptic environment.
The aseptic filling process is a complex task that requires strict implementation of operating procedures to ensure product quality and safety. In the whole process, the aseptic operation is the most critical link and requires operators to have professional knowledge and skills, and strictly comply with the operating procedures. At the same time, the selection and verification of equipment is also very important to ensure that the equipment meets the requirements of aseptic filling.
The implementation of the aseptic filling process is important to ensure product quality and safety. Only under the aseptic conditions of filling operation, can effectively prevent the product from being contaminated, to ensure the effectiveness and stability of the product. Therefore, the aseptic filling process should be highly valued and carried out in strict accordance with the operating procedures. Only in this way can we produce aseptic products that meet the quality requirements and provide patients with safe and effective drug therapy.
Feature of aseptic filling machine
a. Aseptic filling machine provides a variety of safety measures (position control, metering control, temperature control) to prevent mechanical damage and ensure product quality.
b. Aseptic bottle filling machine adopts an electromagnetic flow meter to control the filling volume or adopts a mass flow meter.
c. Aseptic pouch filling machine adopts mirror welding technology to ensure the weld seam is smooth and flat, reducing product residue.
d. Aseptic bag filling machine is equipped with large and small working tables, suitable for packaging of products with different packaging volumes.
e. Aseptic bag filler adopts a programmable controller to realize the automatic operation of the equipment.
f. There are single-head, double-head, tonneau, and four-station aseptic filling machines for large bags.
Use of aseptic filling machine
a. Pre-use check. Before beginning use, make sure the charger's power plug is connected to the power source and the chassis is grounded. Make sure the air pressure in the filler is normal. Check if the motor and bearing lubrication is required. It is strictly forbidden to run the machine without oil. Start the machine only after normal Observe at the same time. Are all liquid storage tanks with a material chain plate on the conveyor belt, are there any foreign objects on the conveyor belt, are there bottle caps on the storage cap track, are water, power, and air sources connected, are all liquid storage tanks with a material chain plate. Whether there are foreign objects on the conveyor belt storage lid track, whether there are bottle caps, whether connected to the water, power, and air sources, and whether connected to each fastener If the parts are loose, ensure that the operation of each part is stable before normal use, and wait patiently.
b. Check safety equipment for proper operation. Check whether the valves of the reaction tank and the piping of the filter unit are tightly connected, whether the filter cloth of the filter unit is damaged, and check for tightening bolts on the lid to ensure no leakage. Filler Pressure. Check all connecting wires associated with the filler unit to make sure there are no broken skins, short circuits, and other defects.
c. Before starting the machine, check whether there is water in all tanks, whether the chain plate is fixed, whether there is debris on the conveyor belt and whether there are bottle caps in the lid of the storage box. Confirm that the water source, power connection air source and air source are ready for standby under all conditions before turning on the main power again. Start conditions are met when the power indicator is turned on and the fault indicator and emergency stop indicator are turned off. Press the start button on the control box and then press the start switch at the charging point, the buzzer will sound three times. After the warning, the whole machine starts to work and enters the fully automatic working mode of washing, rinsing and filling. When the machine stops, press the stop button on the charging position and on the control box and cut off the main power supply after stopping.
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