Fully automatic monoblocks for rinsing, filling with electro-pneumatic filling valves and capping
Fully automatic monoblock for filling sparkling wine bottles
Fully automatic monoblocks for rinsing, filling with electro-pneumatic filling valves and capping
This new generation of electro-pneumatic filling valves demonstrates GAI's many years of experience in the development and production of complex filling systems.
Monoblocks from the FE HP (with flat base plate) and RE HP (with inclined base plate) series are made of high-quality stainless steel and equipped with
- 2-phase rinser, with electro-pneumatic spray nozzles
- High-pressure ring filler, with electro-pneumatic filling valves
- one or two cappers
Electro-pneumatic 2-phase rinser for rinsing bottles with e.g. water and gas. The bottles are gripped by the neck with a gripper and rotated with a cam-controlled rack and pinion system. The nozzle is inserted 75 mm into the neck of the bottle; injection only takes place when the bottle is present.
There is no contact between the bottle neck and parts of the injector. The two injection circuits are completely separate from each other. The timing and duration of the injections are easily adjustable via the control panel.
The dripping liquid is recovered in a closed circuit without wetting the machine.
The high-pressure filler works with the latest generation of electronic filling valves and can be optimally adapted to the different requirements for filling still and carbonated products. The patented filling valve allows filling with a back pressure of 0 to 8 bar. The filling level is infinitely adjustable between 25 and 100 mm below the bottle neck finish and is maintained very precisely. The fact that the oxygen pick-up during filling is reduced to a real minimum also makes the electronic filling valves very gentle on the product.
The design and construction of the filling stations as a 4-valve system has proven to be very advantageous: they ensure virtually foam-free filling and good decompression with very low CO2 consumption. This system significantly increases productivity when filling carbonated products. These valves also make it possible to adapt the individual process steps to the product in question. Hot filling up to 85°C is also possible.
The filling system can be easily and safely cleaned and sterilized using an integrated, patented, automatic cleaning system.
Machines with a capacity of 3,000 bph are equipped with a single-digit capper. In the higher output range, multi-station rotary machines are used, which are fed with caps via a centrifugal feeder (without autonomy).
Monoblocks of the -31 series are equipped with one capper, monoblocks of the -32 series with two cappers.
The rinser and/or seamer can be switched off individually via the control panel.
The monoblocks are included in the scope of delivery:
- Accident protection device in accordance with CE standards with tempered glass doors at the rear and laminated safety glass at the front
- Universal feed screw
- Electric adjustment of the railings
- Sterilization devices with automatic positioning for the rinser
- Set of solenoid valves for switching between gas and scrubbing liquid supply and draining the scrubbing liquid from the circuit at the end of the scrubbing cycle
- Closure lock in the event of filling failure
- Bottle inlet stop and separation at the inlet, as well as bottle exchange switch at the outlet to regulate the bottle flow and possible deactivation of a defective filling valve
- PLC control with touch screen monitor
- Electric height adjustment of all stations
- Shutter detection
- Equipment for a cylindrical bottle type
from a capacity of over 3,000 bph:
- Monobloc inlet and outlet with safety tunnel (length 600 mm), safety switch and inspection window
Note: When filling under high pressure, glass quality is of particular importance. The patented GAI bottle testing machine 45012 offers the possibility of sorting out faulty bottles in order to considerably reduce maintenance work and ensure undisturbed filling and protection of the product.
Performance:
- 3,000 to 15,000 bph
Model overview
| Models | Rinser | Filler | Capper | Wine ltr/h | Sparkling wine ltr./h | Fl./h |
|---|---|---|---|---|---|---|
| 2031 FE HP | 12 | 12 | 1 | 1.800 | 1.100 | 3.000 |
| 2531 FE HP | 12 | 16 | 1 | 2.400 | 1.450 | 3.000 |
| 3031 RE HP | 12 | 20 | 1 | 3.000 | 1.800 | 3.000 |
| 3631 RE HP | 16 | 20 | 3 | 3.000 | 1.800 | 4.500 |
| 4031 RE HP | 16 | 24 | 3 | 3.700 | 2.200 | 4.500 |
| 5031 RE HP | 20 | 28 | 4 | 4.400 | 2.640 | 6.000 |
| 6031 RE HP | 20 | 32 | 4 | 5.100 | 3.050 | 6.000 |
| 7031 RE HP | 24 | 36 | 5 | 5.800 | 3.500 | 7.500 |
| 8031 RE HP | 28 | 40 | 6 | 6.500 | 3.900 | 9.000 |
| 9031 RE HP | 32 | 44 | 6 | 7.200 | 4.300 | 9.000 |
| 10031 RE HP | 36 | 48 | 8 | 7.900 | 4.750 | 12.000 |
| 11031 RE HP | 36 | 54 | 8 | 9.000 | 5.400 | 12.000 |
| 12031 RE HP | 40 | 60 | 8 | 10.000 | 6.000 | 12.000 |
| 13031 RE HP | 44 | 66 | 10 | 11.000 | 6.600 | 15.000 |
| 15031 RE HP | 48 | 72 | 10 | 12.000 | 7.200 | 15.000 |
