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SIDEL ASEPTIC COMBI, DRY DECONTAMINATION

Improve food safety and production hygiene

Scientifically tested and proven through multiple installations in customer plants all over the world, the Sidel Aseptic Combi PredisTM utilises dry preform and cap decontamination for 100%-sterile filling and capping of PET bottles during sensitive beverage production.

 

Sidel Aseptic Combi with dry preform decontamination for sensitive products:

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The Sidel Aseptic Combi Predis offers the market's simplest and fastest aseptic solution with Predis™ dry preform decontamination. It also facilitates the lowest total cost of ownership (TCO) without compromising food safety or production simplicity, and it benefits from high process flexibility, reliability and sustainability. It leverages Sidel's unmatched knowledge of aseptic beverage sensitivity, filling and blowing to provide a unique, proven decontamination solution.

 

Patented dry preform and cap decontamination


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Predis™ technology employs the injection of Hydrogen peroxide (H2O2) into the preform just before it enters the oven. This results in activation of the H2O2 by the existing preform heating stage, ensuring a high level of decontamination while minimising the sterile zone and controlling all risk of potential contamination. Critical parameters are continuously monitored to ensure full production sterility, beverage integrity and food safety, regardless of liquid type or beverage characteristics. The same dry decontamination technology is applied to caps with Capdis™, ensuring a 100% dry aseptic packaging solution when Predis and Capdis are combined.

 

  • The benefits of Sidel Aseptic Combi Predis

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  • Highly safe processing

     

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    The Sidel Aseptic Combi Predis is designed to ensure food safety, product integrity and a longer shelf life for sensitive products without using preservatives. It is built according to hygienic design guidelines from the European Hygienic Engineering & Design Group (EHEDG), and available with 3A configuration compliance for liquid dairy applications.

     

    • Low preform bio-burden level due to integrated blow-fill-cap configuration
    • Easier decontamination, due to preform's smaller surface and smooth shape
    • High level of decontamination - up to Log 6
    • Small aseptic zone - reduced risk of contamination and fewer critical parameters
    • No need for sterilisable blow-moulder - dry H2O2 preform decontamination occurs before oven, preventing recontamination
    • No water usage, no microorganic growth
    • H2O2 residue within bottle ≤ 0.5 ppm
    • Safe and accurate filling - membrane-free magnetic filling, with flow meter control
    • Beverage remains safe in case of extended or emergency stop
    • Safe capping managed by mechanical or brushless capper
    • Excellent microorganic protection - no aluminium foil required with plastic caps, even with UHT milk
    • Efficient external decontamination - more powerful UV lamps for faster, more efficient process

  • Easy operation

     

    Our competitive decontamination solution ensures process and production simplicity.

    • IMG_300x250px_8Integrated single-operator configuration
    • Oven synergy for high-performance processing - chemical, heat and UV
    • Safe, simple and fast changeovers that maintain sterility - mould changeover times reduced to 40 seconds each
    • Easy to maintain - compact and accessible design, with fewer components exposed to chemicals

  • The highest aseptic bottling uptime available

     

    Boosting the continuous production time of your aseptic production, the Sidel Aseptic Combi Predis offers maximum productivity and efficiency:

    • 100% aseptic filling environment with continuous production run of 165 hours between cleaning and sterilisation cycles
    • High productivity - up to 2,400 b/h/m
    • Mechanical efficiency of 95%
    • Reduced downtime for mould changeovers - only 3 hours for cleaning and sterilisation between bottle-to-bottle productions
    • Longer equipment lifespan - components are subjected to less stress over fewer cleaning and sterilisation cycles

  • High production flexibility

     

    Our aseptic output range spans from 10,000 to 60,000 bottles per hour, at production rates up to 2,400 bottles per hour per mould, and is suitable for multiple end product possibilities: 

    • IMG_300x250px_7All sensitive beverages filled, high- or low-acidity, including those with pulp - particle filling capability up to 6 x 6 x 6 mm
    • Suitable for beverages distributed at either ambient temperature or cold chain
    • Same filling valve for dairy, juice and teas
    • Bottle formats from 200 mL to 2 L with any bottle shape, round or square
    • Dual-speed filling - streamlined circuit for recipe optimisation
    • IntelliblowerTM - self-regulation of blow-moulding for top bottle quality and uniformity

  • Cost-efficient and sustainable

     

    Compared to traditional aseptic filling systems, the Sidel Aseptic Combi Predis offers optimal cost-efficiency and environmental footprint:

    • No use of water and almost no chemical use for preform decontamination: H2O2 < 0.7 L per hour
    • At least 10 times reduction in consumption compared with other dry preform decontamination systems
    • Up to 45% reduction in electricity consumption
    • Up to 30% reduction in production costs due to single-operator system Unlimited bottle lightweighting potential

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LOW-OUTPUT ASEPTIC COMBI WITH COMPACT AND LINEAR FOOTPRINT

The low-output Sidel Aseptic Combi accommodates the need for an ultra-compact footprint, facilitating its implementation in new or existing plants:

 

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  • Up to 30 % footprint reduction compared to existing linear solutions
  • Possibility for parallel packaging layout with linear design (typical in milk industry)
  • Unique plug-and-play concept - faster on-site installation, managed while installing rest of line
  • Quick access to key components allows easy management and maintenance