ELL Filling Technology for Gable Top Cartons
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Immediate Attention. Evergreen quality and knowledge comes with US-based technical support and parts for your efficiency. We look forward to working with you to achieve high productivity in-plant and high-quality, safe and convenient product for your customers. Call us at 319-399-3200 Because of the constant improvement program at Evergreen Packaging, Worldwide OEM specifications are subject to change Parts & Services Available without notice. ELL® (Extended Long Life) 2400 Sixth Street SW Filling Technology for Cedar Rapids, IA 52404 USA Ph 319-399-3200 Gable Top Cartons Fx 319-399-3543 The Machines That Capture Freshness [email protected] www.evergreenpackaging.com ELL is a trademark of Evergreen Packaing Inc. E-504 ©2008 Evergreen Packaging Printed in the USA 9/08 1000 CG Keep Your Customers Designing Longer Life Coming Back For More … from the start Evergreen ELL machines represent the state-of-the-art in sanitary packaging design, helping protect your product from potential contamination. Freshness sells. Consumers who discover appealing flavor and appearance inside a Setting the global standard in machine uptime, carton will return to buy again. And again. Evergreen Packaging enables you to produce your products at the “lowest cost to the cooler”. Today, you share the shelf with a staggering number of juice and dairy products — and one Protection starts with a dedicated unappealing experience can send a shopper standard system of pressurized hot to the package next door. Refrigerated Microbiological Shelf Life water (250° F/121° C) decontamination of Dairy Products of product contact surfaces before That’s why processors like you around the world (UHT processing/ELL packaging) operation. (Steam is an option.) rely on Evergreen™ packaging machines to maintain the quality you put inside on day one. , UV 2 Product tanks, metering bowls O and carton fill nozzles are time/ 2 Innovative, reliable, energy efficient and expertly temperature sterilized to the In barrier carton In foil carton engineered — Evergreen’s Extended Long Life All ESL machine options, In standard carton same high standards as aseptic plus double HEPA (ELL®) technologies are made to protect your enclosures, H processing equipment. Advanced shelf power. HEPA* air filtration, chemical sanitation and UV light decontamination systems, which create a “clean room” 20 40 60 80 100 days environment within machine enclosures, provide further Multi-layer HDPE or PET with full body shrinkwrap label. protection, from post- Value-Building pasteurization contamination. 20 40 60 80 100 days Efficiency *High Efficiency Particulate Air What does ELL do for you? Evergreen packaging machines are recognized ELL packaging, combined with UHT processing of incoming worldwide for their accurate fills, assuring added product and packaging alternatives, helps maintain product • Increase plant efficiencies through value for both consumer and processor. quality start to finish. longer production runs • Increase sales at retail; longer pull Evergreen ELL filling technology also reflects dates encourage more facings at retail Evergreen’s commitment to energy conservation, • Drive brand building helping you realize your sustainability goals. As for • Reduce product returns from expired operator efficiency, a single person can oversee short-term pull dates the operation of one or more machines. • Reduce distribution costs; larger, more efficient deliveries possible 2 3 Total, Convenient Control The Gable Top ELL Conveniently located at the infeed, touch- screen computerized controls and monitors Packaging Process are straightforward and easy to use. • Simple – monitor function status at-a-glance • Take a look at how ELL machines can help you Adaptable – change fill volume or timing values achieve superior shelf life performance. at operating speeds without interrupting operation or compromising sanitation • Efficient – run two different carton sizes A Controls (p. 5) simultaneously on quart/liter machines B Clean-In-Place (CIP) (p. 6) • Handy – Changeover manual carton stops and rail height from infeed area Infeed (p. 7) C • Flexible – view maintenance function text in D Carton forming (p. 8 & 9) operator-selected languages* E Sanitizing (p. 10) For convenience, operational sequences such F Filling (p. 14) as CIP and start-up are automated and can be G Sealing and discharge (p. 14) selected as single functions. Air system monitors are found on the HEPA units. And for safety, machine stop controls are located all around the machine. * Languages to be specified at time of order A E F G D B C 4 5 Thorough, Hands-Free Gentle, High-Capacity Clean-In-Place (CIP) Carton Infeed To keep your product as safe as possible, all ELL Machine controls, monitors and high-capacity carton machines are equipped with dedicated, automated magazines at the infeed let your operator oversee Clean-In-Place (CIP) systems. Each system provides the entire filling operation — while keeping the infeed a heat exchanger, pump and controls with all magazines loaded. interconnecting piping. Each magazine feeds an independent form, fill and The CIP system effectively cleans all parts of the fill seal line. This not only provides longer dwell times system, except screen tips, resulting in automatic at sanitizing, filling and sealing stations, but gentler and labor-saving sanitation — with no daily hand product handling prevents liquid sloshing — even at cleaning of fill bowls required. Everything from maximum rated speeds. chemical injection, fresh water flush and thorough CIP system draining occurs on-schedule, according On quart and liter machines, you can: to your pre-defined need. • make carton size changes in seconds • run two different carton sizes simultaneously To reduce wear, only those parts to be cleaned or • adjust manual carton stops from infeed without sterilized are cycled during CIP/SIP (Sterilize-In-Place). contaminating form, fill or seal sections • change carton stops automatically through machine controls PRODUCT/CIP DIVERT LINE VALVE A positive flow of HEPA filtered ENCLOSURES VALVE SPRAY BALL/ air throughout the infeed area VENT VALVE maintains a clean room atmosphere FILTERED and prevents plant air from entering COMPRESSED AIR STERILE the machine. AIR FILTER PRODUCT INLET VALVE STEAM STEAM STEAM STEAM STERILE BURST REGULATOR AIR VALVE DISK HEAT PRODUCT EXCHANGER TANK PRODUCT ISOLATION VALVE PRODUCT SUPPLY METERING CIP BOWLS WATER SUPPLY PUMP WATER VALVE CIP TYPICAL MANIFOLD CIP CIP CHEMICALS SCHEMATIC PUMPS (EQ-5 shown) CIP CIRCULATING/ DRAIN VALVE DRAIN CIP DRAIN VALVE CHEMICAL RESERVOIRS 6 7 Consistent, Leak-Proof Bottom Sealing To save energy costs, maintain product temperature and reduce distortion, bottom ovens heat carton flaps in a selective pattern that permits a proper seal and increases carton strength. While pneumatic pressure assures consistent seals, “dams” apply extra pressure to potential leak paths. Machine reliefs allow for folded layers of paper. To complete the seal, low pressure extends the sealers against the heated flaps; high pressure maximizes closure as the polyethylene cools and bonds the flaps in place. Should an oven fail, the machine automatically stops infeeding cartons until the temperature is restored and the infeed switch reset. If the machine stops, Durable, Sanitary the ovens automatically retract from cartons and a knife of filtered air blows between carton and oven, Carton Forming eliminating risk of fire. Carton blanks are opened, squared and positioned onto mandrels for bottom forming. The mandrels are made from high quality, chemical resistant materials and their design improves the flow of cooling fluid. To prevent potentially contaminating condensation from forming on the mandrels, a semiautomatic system adjusts the coolant temperature to just above the ambient air dew point. The computer intermittenly sprays sanitizing solution on carton contact surfaces before they enter the filling section to maintain a contamination-free environment. 8 9 Automatic, Proven Carton Effective H2O2 & Machine Sanitization HEPA Filter System Exposure Simply spraying H2O2 does not assure For improved sanitation, the ELL auto-sanitizing total sanitization. As Chart A illustrates, system fogs mandrels and sprays top breakers and fill the sporicidal properties of H2O2 depend line enclosures on a customer-set cycle. Manual reset upon its concentration. As concentration assures operator safety. increases, so does its effectiveness. Likewise, its temperature at incorporation influences Before cartons enter the fill section, stationary nozzles effectiveness (Chart B). spray their interiors with an atomized mixture of filtered air and hydrogen peroxide (H O ) preheated 2 2 ELL machines utilize H O at optimum to 120° F (48.9° C). There is a separate system for each 2 2 concentration and high temperature, as fill line. both charts indicate. The resulting logarithmic In the sanitizing chamber, nozzles blow hot, sterile reduction of microorganism has been documented as a “4D kill”, with some users air into the cartons, raising H2O2 temperature to its maximum bactericidal effectiveness. Heated air reporting effectiveness approaching “6D”. continues until the H O vaporizes to residual levels Double Class 100 HEPA Air System 2 2 (Arrows show air f low) below the FDA-required maximum limit of 0.5 PPM. Chart A This performance has been validated by independent 10% laboratory studies and satisfied customers. 100 Chart B 100 10 20% 10 75oF 1 24oC 25.8% 1 .1 .1 95oF .01 35oC