PRODUCT DESCRIPTION
New Design Automatic 600 bottle per hour 5 gallon bottled water filling machine
5 gallon filling machine
One of our core business is today represented by designing and manufacturing of complete lines for 5 Gallon bottles, with a production capacity from 100 to 3.000 B.P.H. the 5 gallon filling lines are designed following 2 main guidelines:
Product hygienic safety: Guaranteed by Tongguan machinery’s advanced washing cycle studied in cooperation with the main multinational chemical companies.
Flexibility: in order to customize the machines on the different requirements in terms of bottle shape, dimension, capacity, washing standard.
Washer
After years of experience in washing process, our washing machine for 5 Gallons, manufactured in different sizes from 100 to 3.000b/h, is able to guarantee the highest level of bottle hygienic quality today on the market.
TIME
The treatment time is the result of a washing cycle which can be customized in terms of number of stations and phases according to the customer standard and requirements. Our recommended washing cycle provides 6 main phases:
1. PREWASH - 2. DETERGENT - 3. FIRST RINSE - 4. SANITIZING - 5. SECOND RINSE - 6. FINAL RINSE
TEMPERATURE
The constant monitoring of the temperature is paramount in order to wash the bottles according to the preset values (between 60 and 65°C). An alarm stops the washer in case these set points are not respected.
PRESSURE
To optimize the washing process, the washer is equipped with high pressure system, which: * Allows to increase the pressure of the washing jet up to 6 bar
* Can be installed on one or more station of the washing phase
* It's particularly indicated for difficult-to-clean bottles (hollow handles, shaped bottles)
CHEMICAL %
In cooperation with the main multinational chemical company, we have developed a cleaning protocol in order to guarantee, after the washing treatment, a bottle consistent to the international hygienic norms and standards. This protocol recommends specific products of different brand, suitable concentration and temperature of the solution (water + chemical product) for each phase of the washing cycle.
MECHANICAL ACTION
* Neck Handling
This patented system to grip the neck of the bottle, guarantees important advantages as: * The possibility to use an high
pressure washing jet
* The washing of the external part of the bottle inside the washer, thanks to the possibility of the bottle rotation under the action of brushes
* The washing of the bottle neck
* Washing Rotating Nozzles
The washer is fitted with double washing rotating nozzles which guarantee the following advantages: * The jet of water hits not only the bottom, but the handle and the walls too.
* The nozzles are self-cleaning (the water flow is inverted at the passing of each bottle) and the washing efficiency is therefore guaranteed.The disassembly for maintenance is considerably reduced.
* The beam carrying the bottles is synchronized with the nozzle even in case of chain extension.
* Rotary Brushing
Brushes are motorised and clean the bottle externally. Since they make the bottle spin, the water jet hits not only the bottom but also the sides of the bottle.
Filler
Fillers for water in large containers fulfills the following requirements: * The filling process avoids the contact between the
valve and the neck of the bottle (risk of contamination transfer).
* The filling process is electronically controlled to ensure into the bottle the predetermined volume of water.
* The filling valve and all the piping, valves etc. in contact with the product have a sanitary design and are made of SS.316
* All parts in contact with the product are prearranged for 3 or 5 steps CIP (cleaning in place) sterilization treatment.
* The filling cabinet is equipped with over pressure air flow. A minimum class 1000 air filtration is guaranteed, so as to protect the filling environment from the external ambient contamination.
* The washer and filler is "in block" in order to avoid the potential contamination of the clean bottles travelling from the washer outlet to the filling area.
Ultra Clean Filler
In order to satisfy the most strict hygienic demands, Bardi has developed an Ultra-clean monoblock with the following features:
* Filling cabinet: * The filling cabinet has been reduced to the essential.
* The cabinet is provided with HEPA filters.
* The execution of the cabinet in aisi 316 without dead ends according to the strictest hygiene design requirements.
* All mechanical and pneumatic gears have been installed outside the cabinet.
* All surfaces are subjected to automatic CIP cleaning.
* Capper: * The caps are treated with sterilized air before entering the high hygiene filling area.
* The bottle leaves the filling room with the cap on top of the neck (nothing can contaminate the bottle).
The PRESS-ON CAPPER
The PRESS-ON CAPPER is a linear machine used for caps applied on the bottle by pressure. It includes:
* Cap hopper
* Canal chute
* Placing system of cap on the neck
* Device to snap the cap on the neck
* Specific systems to sterilize the caps in order to avoid the contact of contaminating agents present on the cap with the bottle neck The bottle takes the cap directly from the canal chute. The snapping of the cap on the bottle neck is carried out through the pressure developed by a belt conveyor, provided with a system to adjust the force in order not to stress the bottle.
Electronic Screw Capper The electronic screw capper stands out because of its operating simplicity and precision.
* The system doesn't require stars, mechanical clutches, or complex lifting mechanisms.
* The closing torque can be set from touch screen; the vectorial frequency converter allows to manage it with high precision.
* The handling parts to move the bottle in the machine are reduced to the minimum, so as the change-over downtimes.
Palletizer Main features:
* 100% machine designed expressely for 5 gallon palletizing (heavy duty application).
* Very simple and reliable machine, which doesn't need brushless motors or any other sofisticated mechanism to work.
* Bottle transfer system from the conveyor to the rack pocket doesn't grip the bottle by the neck. This avoids the manipulation of the cap, which is a very sensitive area.
* The machine is managed by a Touch screen control panel.
* The machine is provided with overload safety device.
* The price, compared to robots, is very competitive.
* Very flexible bottles introduction on the racks, based on a slide + pusher: this ensures much more tolerance than conventional neck gripping mechanism.
The decapper
The decapper is designed to remove the cap from the returned bottles.The Plc manages all automatic and manual functions and allows to records statistics regarding the incoming bottles. This unit can be up-graded to recognize and discard potentially contaminated bottles.
A combination of digital camera and fibre optic detectors allow to reject the bottles returned in the following conditions:
* Bottles without caps.
* Caps without plugs.
* Caps with just the top part left.
* Caps partially opened.
* Not removed caps.
The leak tester is designed to recognize and reject leaking bottles. The working principle is to pressurize the containers for a predetermined period of time and measure the potential losses. The Plc manages all automatic and manual functions and allows to record statistics regarding the faulty bottles.
* Reliable and accurate leak detection of cracks min. diameter of 0,2 mm.
* No bottle mechanical stress.
* Auto-rejection station.
* Touch-screen and microprocessor-based control.
* Robust stainless steel execution.
C.I.P. System
To obtain a good hygienic condition of the bottles, the first step is to sterilize the parts in touch with the product. This can
be achieved through the CIP unit which can work in automatic or semi-automatic modality and with hot or cold solution.
