pr2008 pet cold aseptic filling line
TRANSCRIPT
乐天项目Project of LOTTE Group
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南京乐惠轻工装备制造有限公司是“乐惠实业”的核心企业之一，地处国家级开发区――南京江宁经济技术开发区。 南京乐惠轻工装备制造有限公司是乐惠最新建成的中国规模最大、装备最先进的包装机械制造工厂。 乐惠通过十几年潜心研究，已形成自己的核心技术，以洁净、无菌、环保、节能为主题的PET瓶无菌冷灌装线成功应用于高酸饮料、低酸饮料、中性的含乳饮料。 乐惠的无菌冷灌装技术，不但填补了国内空白，且位列于世界上真正掌握该项无菌冷灌装技术的几个企业之一。
The core enterprise of Lehui Industry- Nanjing Lehui Light Industry Equipment Co., Ltd. is one of the biggest and most advanced packaging machinery plants in Ji-angning Development Zone in Nanjing by Lehui Industry. For the last ten years or so, Lehui has always devoted to the research; Lehui has formed its own technology. The PET aseptic cold filling line based on the clean, as-eptic, environmental, energy sav-ing technology, is successfully applied on high acid beverage, low acid beverage and neutral beve-rage with milk. The aseptic cold filling techn-ology of Lehui has filled the gaps in domestic market; Lehui is one of the few enterprises in the world who has grasped aseptic cold filling technology.
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Huiyuan is the biggest enterprise which adopts cold aseptic fil ling technique on fruit
juice production
汇源是中国最大的采用无菌灌装技术生产无菌果汁饮料的企业。
北京汇源饮料食品集团有限公司成立于1992年，是主营果、蔬汁及果、蔬汁
饮料的大型现代化企业集团。作为民族企业的典范，汇源集团勇于突破常规的生
产模式，开创和引领了中国饮料PET瓶无菌冷灌装的新时代。
Beijing Huiyuan Beverage and Food Group Co., Ltd. was founded in 1992.It is a large and modern group company engaged in producing and marketing fruitand vegetable juice and juice drinks. As a model of private enterprise, Huiyuan G-roup ushered into a new era of PET aseptic cold filling technology in China’s beve-rage industry.
Lehui launched 2000BPH (2.5L) PET aseptic cold filling line in 2001, which runs successfully in Huiyuan shunyi factory (headquarter). Lehui PET aseptic cold filling line has passed national appraisal, and obtain-ed CQC certificate from China Quality Certification Centre. The PET aseptic cold filling line has passed national appraisal which was organized by China National Light Industry Council on 29th April, 2005.
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Product to be filled: 5-100% natural juice, PH<4.6, some products contain pulpproduction capacity: 2000BPH (2.5L)The way to be filled: aseptic cold filling (at ordinary temperature)container: square bottles (250ml), φ38mm, HDPE three lines screw capSterilization efficiency: reach 6logbacteria content of product: ≤1:100,000Aseptic period: >72 hoursResidual PAA :< 0.5ppm
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汇源上海厂两条2.5L线的布置方案
Japan-Toyo Seikan Group was established in 1888, it’s a famous listed company in Japan. The company is mainly engaged in developing and manufacturing PET bottles, metal cans and other packaging containers as well as OEM production for large food and beverage enterprises. The company’s headquarter is located in Tokyo, and has 20,000 employees in Japan, as well as 66 subsidiaries and factories. Toyo Seikan Group has dominated more than 30% market share in domestic and placed fifth in the world packaging industry.
On 11th, February 2006, Lehui set up relationship with Toyo Seikan Group, began to get close touch with each other and communicate technology.On 10th, July 2006, two sides signed 《PET cold filling equipments manufacturing and technical support contract》On 16th, Nov 2006, The first cooperative aseptic line began to be manufacturedIn Nov. 2007, after strict aseptic inspection, every indications of Lehui’s product conformed to requirements and passed aseptic inspection. The first cooperative aseptic line achieved complete success. The product quality and good service of Lehui as well as achievements by both sides were highly regarded by Toyo Seikan Group head office.On 23th, Nov 2007, the grand installation ceremony of this line was held in Toyo pack Thailand factory, the Chairman Vicent Lai and Executive Vice President Tony Huang were invited to attend the ceremony.Through this cooperation, Lehui gained reliable and comprehensive technology of high speed PET aseptic cold filling line.
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Product to be filled: ① coffee and tea (green tea or oolong) ② coffee and tea with milk (use milk powder or concentrated milk)The way to be filled: aseptic cold filling (at ordinary temperature)Container: 280～500mlPET round bottle and square bottle, Φ28mm PCO capCapacity: 400BPM (500mL)Sterilization capacity:≥6Dbacteria content of product: ≤1:1,000,000Residual PAA: ≤0.5ppmAseptic period: 72 hoursCIP/SIP time: approx. 4 hours
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Aseptic cold filler unit, cap sterilization system, each supporting system, auto-control system, packaging system, preparation system etc.
Non-contact filling valve Electromagnetic flowmeter with high precision
The pressure control technology of aseptic balance tank makes pressure more stable and filling volume more precise.
Thin oil central lubrication system makes the drive system run in a good condition and prevents it from being corroded by sterilant gas
The rinsing technology guarantees the sterilization effect of vertical bottle and bottles with salient angle or dish angle
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No cap beating bar when capping
Special shield technology can prevent bacteria into the bottles when the capping head moves up and down.
Auto false cup for CIP/SIP
Air pressure control technology with frequency conversion to keep pressure stable in isolation cover
Isolation cover of the world leading level
Screw sealing technology guarantees the aseptic production period
When equipments are running at high speed, there are no inspecting glovesin isolation cover
Each supporting system is the guarantee for aseptic filling environment, material and containers
UHT plant with CIP device Aseptic water preparation system adopts tubular UHT Disinfectant plant uses flowmeter to measure
so that PAA allocation is more precise and stable
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CIP system
Aseptic tank and aseptic air unitAseptic compressed air is equipped with two-stage aseptic filter which can be used in series
Exhaust gas washing towerAdding water and alkali automatically
Reliable auto-inspection and auto-control system is the guarantee for asepsis maintenance and stability of the production line.
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188mm
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141mm
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141mm
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125mm
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113mm
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113mm
物料Filling material
高酸、低酸、中性产品，如果汁饮料、茶饮料、运动与功能饮料、含乳饮料、以及热敏性差的饮料High acid, low acid and neutral beverage, such as fruit juice, tea drink, sport and functional drinks, beverage with milk, and low thermosensitive beverage
容器container
250mL-2500mL PET、HDPE 瓶(各种盖)250mL-2500mL PET、HDPE bottles(different types caps)
灌装系统Filling system
电磁流量计, 无菌灌装, 非接触, 高精度electromagnetic flowmeter, aseptic filling, non-contact, high precision
产量Capacity
2500bph(2500mL)
4800bph(2500mL)
7200bph(2500mL)
16000bph(2500mL)
24000bph(500mL)
36000bph(500mL)
灌装阀数量Number of fillingvalve
拧盖头数量Number of cappinghead
间距 Pitch
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3.75L
Since Lotte Group was established in 1960s, it has been making for quality priority with superb technique, prime raw materials and advanced equipments. Now Lotte Group has developed 9 more countries including China and Japan.Lotte (China) Beverage Co.,Ltd., founded on 27th ,Sept.2005, is formed by Lotte Chisung Beverage Co.,Ltd.—the biggest beverage company subordinated to Korea Lotte Group. It is mainly engaged in producing and marketing a variety of beverages such as fruit juice drinks, carbonated drinks, functional drinks, alcoholic drinks and so on, the marketing network covers all over the country. Compared with the domestic peers, Lotte was the first beverage enterprise that comprehensively passed the management system certification of ISO9001-2000,ISO14001,HACCP.
In Sept. 2008, a super-clean hot-filling line of 12000BPH was installed in Lotte Austria factory and was formally put into productionIn Dec. 2009, Lotte Huabang bought a 2.5L aseptic cold-filling line of 3000BPHIn Jun. 2010, 2.5L aseptic cold-filling line of 3000BPH has passed the strict aseptic validationIn Jul. 2010, the aseptic cold-filling line was formally put into production
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乐天项目Project of LOTTE Group
乐天公司简介
Introduction of Lotte乐天集团自上世纪60年代投资兴建，自建立至今，始终以最高的技术、最好的原料、最先进的设备为出发点，向品质第一的
目标奋进。目前集团事业已经扩展到全世界包括中国、日本在内的9个国家。
乐天（中国）饮料有限公司成立于2005年9月27日，是韩国乐天集团旗下最大的饮料企业——乐天七星饮料株式会社组建而
成。主要生产和销售果汁饮料、碳酸饮料、功能性饮料、酒类等多种多样的饮品，是国内同行业中第一家全面通过
ISO9001-2000,ISO14001,HACCP等管理体系认证的饮料企业，销售网络遍布全国。
合作历程
Cooperation process between Lehui and Lotte
2008年9月 12000BPH的超洁净热灌装线安装在乐天澳的利
工厂，并正式投入生产。
2009年12月 乐天华邦采购2.5L装3000BPH的无菌冷灌装生产线
2010年6月 2.5L装3000BPH的无菌冷灌装生产线通过严格的
无菌验证
2010年7月 生产线正式投入生产
2.5L
750ml
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乐天项目Project of LOTTE Group
乐天无菌线的工艺流程
Process flow chart of LOTTE aseptic line
乐天线的技术参数 Technical data of Lotte project
乐天无菌线的设备组成和设备的平面布置图 Layout of Lotte aseptic filling line
灌装产品：5-100％的天然果汁，PH值＜4.6，
部分产品含果肉纤维。
生产能力：3,000瓶/小时(以2.5L瓶型计算)
灌装方式：无菌冷灌装（常温灌装）
容 器： 750mL / 2500mL / 3750mL 三种PET瓶
φ38mm HDPE三线螺旋盖
杀菌效率：达到6log；
产品带菌率：≤1:100,000；
无菌化周期：>72小时
PAA残留： 小于0.5ppm
Product to be filled: 5-100% natural juice, PH<4.6, some products contain pulp Production capacity: 2000BPH (2.5L)The way to be filled: aseptic cold filling (at ordinary temperature)Container: square bottles (250ml), φ38mm, HDPE three lines screw capSterilization efficiency: reach 6 logBacteria content of product: ≤1:100,000Aseptic period: >72 hoursResidual PAA :< 0.5ppm