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ECOSpin 2

By GEA Procomac

With ECOSpin 2 GEA Procomac reaches the 6th generation of wet PAA sterilization technology, that focuses on water, chemicals and energy saving.

ECOSpin 2 consists of bottles and caps sterilizer and rinser, filler and capper enclosed within a class 100 Microbiological Isolator, which provides a physical barrier between the external environment and the microbiological controlled area. All relevant internal components can be easily reached through intervention gloves which avoids the operators having any contact with the Sterile Zone.

Format changeover can be performed using manipulation gloves, with no loss of sterility.

GEA Procomac's PAA sterilization technology represents the state of the art for aseptic filling system and it is designed to be effective on every bottle shape to avoid microbiological carry-over into the ?lling area. The choice to use only one PAA solution for bottles internal and external sterilization, environmental sterilization (SOP) and caps sterilization, is the simplest and easiest way to get a robust and reliable sterilization process for bottles and caps.

gea ecospin 2

One PAA solution and only 5 parameters under continuous control, to reach required performance: pressure, temperature, concentration, flow rate and spraying time. Moreover, the PAA solution can be recovered and, once concentration and temperature are restored, reused in a closed loop.

A new sterilizer design without valves allows to simplify maintenance and reduce maintenance costs, guaranteeing the same treatment efficacy.

The new full cone penetrating nozzle used for internal bottle sterilization treatment generates a high pressure PAA solution spray that is able to decontaminate the "Cold Spot" in inoculated bottles. The high-efficiency spraying system keeps treatment time very short.

The efficiency of each nozzle is automatically checked by a "Smart sensor" that ensures proper sterilization of each bottle.

GEA Procomac external bottle sterilization can reach up to 5 log reductions, while the internal bottle sterilization guarantees up to 6 log reduction.

Internal and external sterilization of the bottles are always performed at the same time to avoid any risk of cross contamination and of microbiological carry-over into the filling area. This ensures GEA Procomac's lines continuously operate under aseptic conditions without any intermediate environmental sterilization cycles (SOP), maximizing the production time: ECOSpin 2 runs continuously for up to 120 hours when filling not only high acid but also low acid products.

ecospin2

It is a unique achievement in the market, since the filling of low acid products into PET, when performed aseptically, traditionally requires a cleaning/sterilisation cycle every 72 hours. Whereas, the ECOSpin 2 can run continuously for up to five days: in this way it is estimated that ten additional production days per year can be achieved, significantly reducing the cost per bottle and having a very positive effect on its environmental impact.

ECOSpin 2 uses GEA Procomac's volumetric electronic filler Fillstar FX fitted with magnetic flow meters, an industry standard for filling sensitive beverages: the Fillstar FX can fill any beverage including products with pulps, fibres or fruit pieces. The bottles are neck handled throughout filling and capping.

The GEA Procomac recently introduced Dual Filling system for beverages containing pulps, fibres and pieces with dimensions up to 10x10x10 mm can be integrated in the ECOSpin 2 technology. Dual Filling system is composed by two different fillers: the new Aseptic piston doser PX for solid particles and the above mentioned Fillstar FX for filling still beverages. This is believed to be the first time this process has been used in a cold-fill environment for PET bottles.

ECOSpin 2 is equipped with all the necessary process units to produce sterile water, peracetic acid solution, the cleaning unit and the filtration of all the fluids.