Compressed Air Applications

Packaging

Compressed air can be used to generate vacuum used in the packaging process, air is also used in conveying systems to move food and ingredients.

Bottle Filling

When beer is bottled, its residual oxygen content must be kept as low as possible. To this end, breweries employ two different methods, either alone or in combination. Bottles are flushed with CO2 and filled with beer via a long-tube filler. In this case, the filler tube is inserted into the bottle and the bottle is flushed with carbon dioxide before actually being filled with beer. This method consumes a relatively large amount of CO2. Bottles are evacuated and then flushed with CO2. This method greatly reduces carbon dioxide consumption because most of the oxygen is already extracted.

PET bottle blowing

High pressure oil free compressed air is fed into the bottle blower machine moulds where preforms are heated and the plastic is streched to form the bottle.

Product handling

Air hoists and cylinders are used to move products, at very high speeds able to keep up with modern production practices.

Food filling machines

Food filling machines use compressed air to fill products such as cakes, pies, and liquid products.

Fluid pumps

Compressed air is generated to operate pumps such as diaphragm pumps to move liquid products in the production and filling process.

Nitrogen Generation

Nitrogen generators produce nitrogen from compressed air supplied by a dedicated air compressor. The compressor is mounted at the beginning of the system and passes compressed air through sets of filters to remove the impurities before entering into the generator. The filtrated air then passes through another filter that eliminates oxygen and carbon dioxide molecules resulting in a high purity of hydrogen gas.

Air knives

Compressed air is used as a clean medium for cutting products. It is also used for peeling products such as fruit and onions.

Blower and Vacuum Applications

Filtration

Filtration units are used for filtering and cleaning liquids. The choice of the filtration membrane (nano-, ultra- or microfiltration) depends on the product requirements. Crossflow filtration, for example, involves re-circulation of the feed stream across the membrane surface caused by the pressure difference between retentate and permeate. During the filtration process, particles deposit on the membrane surface which are gradually removed by the cross flow velocity generated by the pump to minimise polarisation.

MAP storage and packaging

To prevent fruits or meat from maturing, they are stored in cooling chambers under so-called controlled atmosphere conditions: after having been exhausted, the cooling chamber is filled with inert gas. Alternatively, the inert gas is carefully compressed into the packaging.

Filing and closing machines

When bottling beverages, cosmetic or pharmaceutical products, the bottle is at first evacuated before being filled to make sure the product reaches the customer in good quality.

Bottle filling

When beer is bottled, its residual oxygen content must be kept as low as possible. To this end, breweries employ two different methods, either singly or in combination:

Bottles are flushed with CO2 and filled with beer via a long-tube filler. In this case, the filler tube is inserted into the bottle and the bottle is flushed with carbon dioxide before actually being filled with beer. This method consumes a relatively large amount of CO2.

Bottles are evacuated and then flushed with CO2. This method greatly reduces carbon dioxide consumption because most of the oxygen is already extracted.

Packaging

The surrounding pressure exerts a mechanical influence on the product that can greatly alter the external shape. For this reason, the MAP process has been the method of choice in many application areas. In this process, products are packaged in modified atmosphere and the oxygen removed. The product is enclosed in a blister package, placed in the vacuum chamber and evacuated. The modified atmosphere is then injected and the blister package and food are sealed with a protective film.

Using this method the food retains its original shape and meats present a suitably red appearance to customers, even after extended storage.

Evacuation

The packaging process has numerous requirements for vacuum pumps, as during evacuation of only air, but also water vapour, fat and spice mixtures are evacuated. Because of higher requirements for quality of food with regard to flavour, colour, homogeneity and durability, meat processing uses more and more vacuum, too, e.g. in filling machines, tumblers and cutters.

Dairy processing and milking

On yogurt filling machines the vacuum pump serves to position the lids on five pre-filled yogurt containers simultaneously. Suction cups on the machine grip the lids, separate them and move them into the correct positions. n addition to transporting the milk, the vacuum used in milking systems performs other tasks as well, such as attaching onto the udder and holding the weight of the milking claw assembly to the teat.

Liquid ring pumps and side channel blowers offer significant advantages over traditional oil-lubricated pumps because they use no oil. The side channel technology has the additional advantage of requiring no water connection – and it is optionally available with frequency converters.

Preservation of cooked food

Fruits, vegetables and their subsequent products, such as mash and purée, are preserved through cooking. This involves heating a small amount of water to generate steam which removes the air. To obtain a high product quality and energy efficiency, the preservation process is carried out under vacuum.

Humidification

Tobacco packed in bales is so brittle that without proper humidification it would crumble into dust when processed further. A vacuum pump extracts the air from the bales and replaces it with steam, sometimes supplemented with aromatic substances. This approach is also used for other types of food in need of humidifiation.

Evisceration

Before any further processing can take place, fish and molluscs must be gutted and cleaned. Worktables are outfitted with suitable vacuum nozzles that extract the entrails from the fish. A central vacuum system then pipes the combination of liquid and coarse particles through a filter where they are separated for proper disposal. The same is possible in the poultry sector.

Sterilizing of tea and spices

Tea and spices imported from tropical regions are shipped in bales, which very often contain pests, insects, fungi and bacteria that must be destroyed before further processing can occur. This is done by placing the bales in vacuum containers and extracting the air. The bales are then injected with steam or a sterilized gas.

Cutters

To produce sausages a meat mixture is chopped into small pieces and mixed with spices and other additives. Extracting air during the chopping and mixing processes can help prevent the mixture from oxidizing, which would have a negative effect on the sausage’s flavour and appearance. The air is evacuated by means of a vacuum of about 100 mbar. The pump used must be insensitive to the meat particles and liquids that are also extracted.

Drying

Many food stuffs need to be dried during the production process and vacuum is used for that purpose.

Filling

Whether your company is expanding filling production capabilities, modernizing existing lines, or designing a fill-line from the ground up, MAC Valves Inc., is a global leader in filling industry valves, to keep your machines running smoothly around the clock and around the world. Proven to optimize cycle times and significantly improve fill consistency, MAC’s Bullet Valve®️ technology offers speed, reliability, and cost savings.

The MAC Bullet Valve®️ features and benefits:

• Calibrated stroke valves for filling applications that DON’T STICK
• Dependability with double diaphragm technology makes MAC valves last longer and perform better
• Balanced design
• High flow, highly-engineered design allows valves to easily handle high flow
• Simplified changeovers minimize downtime and the cost of ownership with valves that are easy to install and maintain
• Maximized output
• Low wattage and leakage versions are available

The 2-way and 3-way configurations of the MAC Bullet Valve®️ cartridge are available in sizes 10mm, 14 and 21mm (up to 1.000 Nl/min) – with other modifications available

Meat Processing Equipment

PHD ensures product safety and quality for compliance with USDA regulations. They offer meat processing equipment for processes such as conveying, labeling, and packaging. Allowing you to optimize your automation efficiency.

direct contact food picking

Food products comes in varied shapes, sizes and consistency that requires you to pick the right type of solution. Vacuum systems fitted with right type of suction cup and vacuum ejector can be the most versatile and reliable solution. Suction cups from Piab come in a large variety of geometries and materials to provide a secure seal without damaging the goods. Their cups are made from food grade materials and meet all current FDA requirements.

Due to the large variety of shape, sizes, and consistency of food products, an adjustable vacuum level will be key to avoid product marking or damage. Piab offers a wide range of vacuum ejectors with all the functionality you may require in high performing picking and placing operations.

All their food contact classified products are easy to clean and require minimal maintenance. Additionally, the vast majority of their products are configurable and modular, which helps to simplify operations and get you up and running quickly and efficiently.

INDUSTRIAL COLLABORATIVE ROBOTS IN FOOD & BEVERAGE

UR cobots are used throughout the food and beverage supply chain in a wide range of secondary processes such as packaging and machine tending. Collaborative robots can work in conditions from humid greenhouses to refrigerated rooms to tending hot ovens, relieving employees from repetitive tasks that can cause injury in unfavorable environments.

Cobots excel in low-touch processes, and can work around the clock without breaks. This is ideal for seasonal bursts, where cobots can meet productivity requirements without the need for additional temporary workers. Flexible, easy-to-program cobots can then be redeployed to new product lines or different processes. With no need for safety fencing (after risk assessment), cobot-based production or packaging lines can be easily reconfigured, adding value for even for low-volume runs.

For pick/pack/pal applications, UR cobot models meet a range of reach and payload requirements. Built-in palletizing wizards make deployment a breeze, even to meet specific customer needs for pallet patterns and labeling that are often required for food and beverage distribution.

Sensor solutions for continuous conveyors

Continuous conveyors ensure the continuous flow of goods. The presence of goods must be identified in the system, dimensions and fill levels checked, and bar codes must be read reliably. This guarantees a seamless production process. A comprehensive range of sensor solutions facilitates safe and fast object detection and protects people and the system. Individually deployable reading principles, such as bar code, 2D-code, and RFID guarantee maximum flexibility. Our sensors offer reliable detection through high performance reserve even with glossy, dark or stretch-wrapped packages, and rough environmental conditions. The intelligent mounting technology, fast alignment, and easy integration into existing systems such as PROFINET by means of fieldbus interfaces enable swift commissioning of our sensors.

• Object detection with light-band / RK 46C.DXL3 VarOS
• Projection monitoring for pallet loading / CSL 710, CSL 505
• Access guarding without muting sensors / MLC 530 SPG
• Safeguarding of pallet transfer stations / MLD 300, MLD 500
• Pallet identification / BCL 500i
• Object detection / 318B, 5, 25C, 28, 46C series
• Fill level monitoring / LRS 36
• Container identification / BCL 300i
• Volume measurement / LSC 200
• Carton identification / BCL 600i

Tolomatic electric actuators provide:

• Hygienic design
• Infinite positioning
• High accuracy and repeatability
• Simplifies machine design by eliminating the need for protective guards/ enclosures
• Stainless steel design resists corrosion
• IP69K wash-down protection
• “Clean-in-place” flexibility
• Energy efficient operation