Aseptic filling system for sensitive beverages
Optimize your beverage production with an aseptic filling system that ensures product integrity and reduces contamination risks, allowing you to explore new, premium formulations without compromising on safety or quality.
Sterilizes, Fills, and Caps Sensitive Beverage Containers
The GEA Aseptic Filling Pilot Plant is engineered to support beverage and liquid dairy producers by sterilizing, filling, and capping containers under aseptic conditions, minimizing contamination risks and optimizing product integrity. This modular system offers flexibility, accommodating a vast range of bottle sizes and materials, including PET and HDPE, with a sustainable dry sterilization process utilizing vapor-phase hydrogen peroxide for up to 6 log reduction in contaminants.
Designed for pilot and R&D settings, it seamlessly integrates into existing production lines, allowing for scalable evaluation and testing of new beverage formulations. Catering to a variety of applications, it can handle sensitive beverages, both high and low acid types, with or without particulates, and includes a unique aseptic piston doser for precision dosing of large or delicate particles, ensuring high filling accuracy.
With a focus on process optimization, the plant is equipped for fully automated changeovers, transitioning from contact to non-contact filling, while maximizing food safety. The system’s energy efficiency is enhanced by its non-water-reliant sterilization method. It supports strategic investment decisions by allowing on-site customization to meet specific product development requirements, enabling the production of small-scale batches without disrupting routine operations.
Benefits
- Reduces time-to-market by enabling efficient testing and development of new beverage formulations.
- Minimizes contamination risks with aseptic filling and capping processes.
- Enhances flexibility with customizable configurations for various bottle sizes and materials.
- Lowers operational costs through waterless sterilization using vapor-phase hydrogen peroxide.
- Streamlines scale-up from pilot to full production with modular design integration.
- Applications
- Carbonated beverages,Milk-based drinks,Sensitive beverages,High acid beverages,Liquid dairy,Innovative beverages,Premium beverages,Low acid beverages,Particle-containing beverages,Still beverages,Fiber-containing beverages
- End products
- Probiotic drinks,Herbal infusions,Oat milk,Cola drinks,Cream-based drinks,Tamarind soda,Orange soda,Greek yogurt beverages,Cold brew coffee with milk,Strawberry cream soda,Dairy alternatives,Almond milk,Microfiltered milk,Sparkling water,Energy drinks,Aloe vera drinks,Enriched milkshakes,Milk with cereal particles,Liquid meal replacements,Chocolate milkshakes,Fruit juices,Flavored water,Cranberry juice cocktail,Flavored milk drinks,Fizzy lemonade,Enhanced mineral water,Functional water,Vegetable juices,Lactose-free milk,Coconut water with pulp,Dairy-based smoothies,Carbonated soft drinks,Kombucha,Pineapple juice with pulp,Plant-based milk,Lemonade,Kefir,Exotic smoothie mixes,Premium juice blends,Iced tea,Fruit nectars,Apple cider
- Steps before
- Raw ingredients mixing,Initial product preparation,Thermal product treatment
- Steps after
- Capping,Hermetic sealing,Aseptic packaging
- Input ingredients
- raw ingredients,liquid products,PET containers,HDPE containers,additives,carbonated beverages,still beverages,high acid beverages,low acid beverages
- Output ingredients
- sterilized bottles,capped bottles,aseptically filled packages,innovative beverages,premium beverages
- Market info
- GEA is known for its expertise in engineering innovative and sustainable equipment and solutions, focusing on sectors such as food, beverages, pharmaceuticals, and energy, with a reputation for quality, efficiency, and advanced technological applications in industrial processing.
- Automation
- Fully automated changeover
- Filling volume
- 100 ml to 3 L
- Sterilization method
- H₂O₂ vapor
- Log reduction
- Up to 6 log
- Filling method
- Contact and non-contact filling
- Container material compatibility
- PET,HDPE
- Particle dosing method
- Aseptic piston doser
- Energy type for sterilization
- Dry process,no water consumption
- Filling accuracy
- Maximizes particle filling accuracy
- Working mechanism
- Aseptic filling
- Integrated steps
- Sterilizing,filling,capping
- Batch vs. continuous operation
- Batch
- Automation level
- Fully automated with changeover options
- Energy efficiency
- Sustainable dry sterilization
- Cleaning method
- Dry sterilization
- Changeover time
- Automated changeover process
- Abrasion resistance
- Yes
- Cleanability
- High
- Biological compatibility
- Suitable for food/beverage
- Corrosive resistance (e.g. acids)
- Yes
- Density/particle size
- Various liquid types
- Container Compatibility
- PET,HDPE
- Chemical Compatibility
- H₂O₂ vapor
- Discharge method
- Aseptic capping station
- Flexible filling module
- Handles 100ml to 3L bottles
- Interface
- Automated changeover
- Material compatibility
- PET,HDPE
- Sterilization process
- Dry H2O2 vapor
- Control panel type
- PLC/HMI integration
- Container versatility
- 100 ml to 3 L
- Bottle material compatibility
- PET,HDPE
- Cap variety
- Different sizes/shapes
- Module installation
- Stand-alone/module integration
- Filling head options
- Dedicated for large/hard/fragile particles
- Sterilization process
- Dry using H2O2 vapor