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Modulbloc

By GEA Procomac

Using Modulbloc, the aseptic filling technology from GEA Procomac for low/medium speed lines, it is now possible to bottle sensitive beverages making them shelf stable without the use of preservatives.

Its compact design makes Modulbloc the right choice for every kind of facility even when limited space is available. The system includes a sterilizer carousel, a rinser carousel, a filler carousel and a capper all on a single base frame. The ancillaries aseptic process units and the cap sterilizing machine are located on top of the machine.

The machines are enclosed in a Microbiological Isolator which provides a physical barrier between the external environment and the microbiologically controlled area. The environment is sterilized before starting production with a spray solution of Peracetic Acid (PAA). The sterility is then maintained with an overpressure of sterile air.

gea modubloc

Modulbloc uses Peracetic Acid (PAA) as the sterilizing medium to achieve up to 6 Log reduction in packaging microorganism decontamination. Once the bottle is externally and internally sterilized, it is rinsed with sterile water, transferred to the filler and filled using the most flexible GEA Procomac technology: Fillstar FX filler range for products with or without fibers, particles or pieces; Fillstar CX filler range for carbonated products; and the recently introduced Aseptic Dual Filling system to fill products with pieces up to 10x10x10 mm.

Ancillaries are reduced to only two units, that are integrated into the aseptic filling system: Ecodox, placed beside the Modulbloc, that provides diluted peracetic acid used as bottle and cap sterilant, and Ecoflux, positioned on top of the machine, a compact solution that integrates in one skid sterile water microfiltration (FDA approvable) and steam, compressed air and nitrogen gas filtration. Sterile water for caps rinsing and for PAA dilution is produced by microfiltration.

Modulbloc is also available in ESL version for products filled in a clean environment at ambient temperature and distributed using a refrigerated supply chain. After sterilization step, performed with spray PAA solution to achieve a minimum of 3 log reduction on specific microorganism, bottles can then be filled using the complete GEA Procomac FX range of valves, thanks to which GEA Procomac earned, the first companies in this sector, the 3A international certification. Once the bottle is filled, it is capped using a capping machine in ultraclean version. The machines are enclosed within a separate, clean environment protected by overpressure micro-filtered air.

By assembling nozzles in different configurations in the sterilizer, rinser, filler and capper, it is possible to achieve different machine speeds, starting from the M.3 (pilot plant) to the M.33.33 (higher speed).

Short time to market, if compared to high speed aseptic technologies, is also increasing the Modulbloc success.