krones Contiform Bloc Stretch blow moulder and filler in an effective combination

krones Contiform Bloc

Stretch blow moulder and filler in an effective team. And that is the reason why we have perfected the popular combination of both machines even further in a single block in the form of the Contiform Bloc. With a seamless drive concept, finely tuned transfer interfaces for every production pro-gram and precisely operating process-es in stop situations, you can count on getting the very most out of your PET bottle line.

Compact, economical and flexible – that is the Contiform Bloc for all applications. Because it is able, of course, to process every type of prod-uct supplied in non-returnable PET containers available on the market and also enables everything from aseptic filling processes to hot and cold bottling as required for the pro-cessing of liquid products in PET bot-tles. What is clear is that when it comes to container design and vol-ume, you have absolute freedom because the Contiform Bloc really demonstrates its strengths in flexible production processes. And your staff can therefore make the most of their potential, as the compact line allows great freedom for efficient planning.

Bringing together what belongs together

krones Contiform Bloc

Method of operation

The Contiform Bloc combines the Contiform stretch blow moulder in direct modular design with the Mod-ulfill filler – including capper. The individual machines can be disen-gaged from one another quickly in stop situations with the help of the central controller and the servo drive concept. This cuts out long start-up phases when restarting. Integrated inspection and rejection units ensure that the production flow is always monitored immediately at critical points.

Applications

■ Production of non-returnable PET containers with volumes of up to 3 litres

■ Filling concepts for water, soft drinks, milk and mixed milk drinks, fruit juices, teas, cooking oil, beer, wine and ketchup

■ Aseptic production processes (H2O2, PAA), hot and cold filling processes

■ Processing of round and light-weight bottles

Version variants

■ Contiform Bloc BF Stretch blow moulder and filler/capper

■ Contiform Bloc BL Stretch blow moulder and labeller

■ Contiform Bloc BFL Stretch blow moulder, filler and labeller

Figures, data, facts

■ ErgoBloc L wet section block Blow moulder, labeller and fill-er with advance labelling of the freshly blown PET bottles before filling

Outputs

■ 8,000 to 81,000 containers per hour

krones Contiform Bloc

Contiform 3 stretch blow moulder

■ High performance with the new blowing station With a station output of 2,250 con-tainers per hour, a highly efficient stretch blow moulder is integrated in the block concept.

■ Low compressed air consumption Thanks to the electromagnetic stretching system, further mini-misation of the dead space vol-ume and the new “Air Wizard Plus” compressed air recycling system, compressed air consumption is reduced to a very low level.

■ Energy-efficient machine concept Further improvements to the infra-red oven result in significantly reduced energy consumption.

Block components Contiform 3 stretch blow moulder

Preform transfer to the blowing station

krones Contiform Bloc

Modulfill filler

■ Use of all Krones PET Modulfill systems for custom-tailored con-cept development for each appli-cation

■ Integration of all standard PET cap-per solutions in the Modulfill

■ Cap infeed by Krones Capcade ■ Use of a Krones cap inspector to

ensure that the Contiform Bloc continues operating even in the event of faulty caps

■ Hygienic design with reduced sur-faces in seamless self-draining design

■ Precision drive technology with systematic use of servo drives without mechanical drive compo-nents

■ Optimum accessibility to the machine with maximum user-friendliness and simplified manual cleaning.

■ Filler valves and valve surround-ings designed to be gentle on the product

■ Lifting unit for the PET bottles in the neck handling system with no lift cylinders

Block components Modulfill filler

Capcade cap feed

Connected directly – the Modulfill filler

krones Contiform Bloc

Design features

■ Controlled block conditions A partition between the stretch blow moulder and the filler pre-vents any impairments to machine workflows from media or air.

■ Transfer of hygienic bottles Since the bottles are transferred directly to the filler, they can be processed immediately after the stretch blowing process without any risk of recontamination from the surroundings.

■ Sterile filtered blowing air The stretch blow moulder can have sterile filters fitted in the com-pressed air supply as an option. The blowing air will then be abso-lutely clean in hygienic terms.

Bottle guides

■ Short paths for the bottles After the stretch blowing process the bottles are transferred direct-ly to the enclosed transfer star-wheels of the filler – with only short conveyor sections.

■ Controlled bottle guides The continuous guidance of the containers is monitored through-out on the neck ring. This elimi-nates scuffing and other types of damage.

■ Quick format changes With the seamless transfer con-cept for containers on multifunc-tional clamping starwheels and the controlled clamps, no adjust-ment work is required on the guide units when the format is changed.

Block components

Controlled and reliable transfer of preforms and containers

krones Contiform Bloc

Drive concept

■ High-performance servo drive technology The servo motors throughout the entire block offer ultra-precise syn-chronous operation without play at all times, resulting in operat-ing characteristics of absolute precision across the full range of speeds.

■ Stand-alone mode or block mode Servo joint control (SJC) permits individual machines to be disen-gaged electronically in the event of a malfunction and the line com-ponents to be emptied in a con-trolled manner followed by stand-by operation.

■ Quick resumption of normal operation The facility for engaging the machine even at full speed means that with production stoppages being no more than a matter of seconds there is practically no loss of efficiency.

Block components

SJC drive technology in practice

■ The machines can be run either as single machines or in block mode. The operator selects the mode of operation.

■ This allows test operation of the blow moulder, cleaning processes for the filler or even jog mode for the labeller, for example.

■ During production the machine runs in block mode. If a malfunc-tion occurs, the system disengag-es automatically. The operator can rectify the malfunction and the system synchronises itself after it has been acknowledged and resumes production.

■ The filler and labeller can therefore be emptied unhindered if there is a quick stop in the blow moulder. What is more, the blow moulder continues to be ready for produc-tion in the event of a production stoppage in the filler – the infeed of the preforms will stop and the oven will be emptied.

Bottle transfer with Monotec starwheel columns

krones Contiform Bloc

Inspection and monitoring technology

■ High efficiency in the production workflow Precise monitoring devices spe-cifically modified for the machine concept enable faulty preforms, bottles, caps or labelled bottles to be rejected.

■ Integration the control panel The display for a possible over-load of the drive system and the controlled disengaging of block machines ensure that safe and reliable operation within system limits is maintained.

Operation

■ Overview of operational processes The integrated operating and vis-ualisation concept with Krones iPanel provides the operator with a quick overview of all line compo-nents.

■ Information – right on the spot Logically arranged iPanels on the Contiform Bloc provide the basis for the block to be efficiently oper-ated by just one operator.

Line components

Inspection of the PET bottles with PET-View

krones Contiform Bloc

■ Efficient and profitable The quick change-over when-ever the bottles or products are changed and the effective strategy for disengaging individual block elements in stop situations ena-bles you to achieve maximum per-formance for your entire produc-tion program.

■ Compact layout Combined machine concepts save space. The Contiform Bloc offers all the functions without buffer and conveyor sections and is therefore the ideal solution for many con-fined spaces.

■ Convenient for the operator The Contiform Bloc offers a good overview, short paths and a stand-ardised operating concept. It also requires little work for change-overs and has an optimised main-tenance program thanks to the use of servo technology.

■ High standard of hygiene Having only a few interfaces and conveyor sections are key fac-tors in achieving a high degree of cleanliness for the bottle material. The direct transfer of the bottles from the stretch blow moulder to the filler and capper prevents dirt being brought in.

■ Gentle on the bottle Neck handling is the optimum solution for PET bottles. And a low number of transfer stations. Com-bine these features in the Contiform Bloc and top bottle quality is assured.

Your advantages

IT solutions

The SitePilot modular system includes IT solutions which we devel-oped especially for the beverage and food industry. Whether you want to increase the utilisation of your line capacity, monitor product quality, or make spare parts handling more effi-cient: With SitePilot, you will always get the best result.

Lifecycle Service

Your company is unique – why be sat-isfied with conventional solutions? The Krones Lifecycle Service will sup-port you and your production also after the purchase of new machines. These are services which are individu-ally tailor-made to suit your products and location.

krones Service Line

You need support with a techni-cal problem? Or you have an urgent question about you line? No problem: We are just a call away from you. Dial +49 9401 708090 to get quick and straightforward assistance – in sever-al languages around the clock!

enviro

High-performance technology with low consumption of resources offer-ing safety for humans and the envi-ronment – this is all guaranteed by the enviro sign. TÜV SÜD (technical control board) as an impartial asses-sor has confirmed, that the enviro method leads to energy- and media-efficient and environment-compati-ble machines and lines.

krones Academy

Make your colleagues high perform-ers: The training of Krones Academy provides first-hand trade information proven in field. You will find the suit-able know-how package for almost any field and hierachy level ranging from technical courses to manage-ment training.

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krones agBöhmerwaldstraße 593073 NeutraublingGermany

Phone +49 9401 70-0Fax +49 9401 70-2488E-mail info@krones.comInternet www.krones.com