H2O2 injection star wheel and camera control system

Hot air injection control system

Injection control system

Once the first phase in the infeed star wheel has been completed, the containers enter the rotating carousel where the peroxide activation phase is initiated using hot air at temperatures of 110-120°C (or steam at 121°C). Also during this phase, control of the hot air (or steam) injection times is of fundamental importance; this is carried out by solenoid valves, operated by the PLC.

The machine is equipped with safety devices that control the efficacy both of the “atomizer” nozzles and of the blowing nozzles; if a nozzle were to malfunction, this would, in fact, result in the failure to sterilize the corresponding container. In the event of a nozzle malfunction, the machine stops in a preset position so as to allow the operator to remove the unsterilized bottle (an automatic ejection system of the bottle also exists, as an optional).

The machine is also equipped with a hot air (or steam) temperature control system consisting of probes positioned on the ends of the blowing nozzles; if the temperature is too low, the machine stops in order to avoid the risk of the peroxide not being activated and the containers not being sterilized. In order to reduce possible traces of peroxide, reaching residual concentrations of less than 0.5 p.p.m., it is possible to add a third rinsing phase of the bottles with sterile water, if steam is used as the fluid used for activating the peroxide.

If, on the other hand, hot air is used (patented technology), this guarantees high levels of decontamination of the containers (even higher than log 5) even with short treatment times, leaving the said containers completely dry.

In order to guarantee the perfect cleaning and decontamination of the containers, the machine may be equipped with a filtered air laminar flow cabinet using HEPA filters; in this way, the area in which sterilization takes place is kept in a state of slight overpressure, allowing the air to flow towards the outside, thereby avoiding possible sources of contamination. The containers reach a high level of decontamination and arrive at the filling phase in the required conditions of hygiene and sterility.

This is a rotary sterilizer, which can sterilize any type of container (jars included) using hydrogen peroxide (H2 O2) in the liquid or gaseous state.

During the first phase, hot air is injected at a temperature of approx. 80°C to pre-heat the jar; in the second phase, nebulized hydrogen peroxide is injected at concentrations of 30%.

A third phase with hot air (approx. T=100-110°C) enables any hydrogen peroxide residues inside the containers to be removed. Instead of hot air, saturated steam at 121°C can be used as a fluid to activate the hydrogen peroxide itself and make it evaporate, thus enhancing its oxidative power.

Hydrogen peroxide is injected through special “atomizing” nozzles, so as to completely cover the inner wall of the container with a thin film and substantially reduce the amount required for each container (0,5÷2ml.). These small amounts of H2 O2 are injected for very short periods, that is within a few tenths of a second, and it would be very difficult to control such times if mechanically operated spraying valves were used.

The injection times of the various cycles are therefore completely controlled by an electronic system; each nozzle is powered by a solenoid valve which, in turn, is activated by the PLC controlling all the phases of the machine. This guarantees maximum flexibility of the whole system and optimization of consumption.

The machine is equipped with a laminar flow cabin to ensure complete cleaning and decontamination of the containers.

Detail of machine interior

Sterilizing nozzle detail