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Airstar is the first truly aseptic blow moulder and it is an integral part of the ABF system. It was designed by GEA Procomac to have asepsis as a core concept from the beginning.
The preform VHP treatment sterilizes the internal and external surface of the preform using a flow of Vaporized Hydrogen Peroxide at controlled temperature and concentration. This achieves a preform sterilization performance of up to 5 log reduction. |
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In the final stage of the sterilization process, the preform enters the Sterile Zone, where the blowing wheel is located.
A key design decision was to blow the preforms “upside down”, enabling all non-cleanable components to be located outside the sterile zone.
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Electrical components are located above the sterile zone. Mechanical components and all components that require lubrication are located below the sterile zone. All surfaces in the sterile zone are accessible and can be cleaned by foaming and sterilized by a sterilization cycle with VHP, performed before starting every production cycle.
The active pressure modules and the modulating exhausters control the flow of air, sterilized by HEPA filters. This ensures the sterility of the environment which is maintained continuously in sterile air overpressure. |
The sterile preforms are blown with sterile air. The sterile bottles are then turned into the upright position and transferred to the Aseptic Filling carousel.
Airstar technical aspects
- The blowing process
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The blowing process of the sterile preforms is performed with sterile air; this requires both the use of micro-filtration for the sterilization of the air and the sterilization of the piping with VHP. For this reason GEA Procomac developed a specific air blowing block that can be sterilized keeping at the same time reactivity, reliability, “reduced pressure drop” and “reduced dead volume”.
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- Sterile stretching rod (International Patent pending)
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All the parts that touch the preform and/or the bottle have to be sterile before starting production and therefore it is mandatory to have a sterile stretching rod. The GEA Procomac system (patent pending) allows the stretching rod to be kept inside a sterile housing, sterilized with VHP. The movement is forwarded by a magnetic joint between two magnets: an internal one connected with the stretching rod inside the housing and an external one connected with a standard moving system by cam and pneumatic actuator. This also provides the benefit of allowing the automatic disengage of the magnets if jamming of the preform occurs during the stretching phase.
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- Locking system (European Patent)
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Several features of the ABF also have patents pending. One of the most interesting is the new moulds locking system. Two rings have a symmetrical movement and lock the two moulds together. During the blowing process the load will be applied to the rings without the need of a pneumatic compensation system. This reduces the number of components, minimizes air consumption and especially avoids the need to sterilize the “little” compensation chamber.
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- Sterile process continuity
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The sterile bottles, after being turned into the upright position, are transferred to the Aseptic Filling carousel without leaving the sterile zone. The blow moulding machine and the filler are synchronized electronically in the same way used for the traditional system.
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- Changeover
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Change-over of the moulds is performed in a specific isolated area under a laminar air flow generated by an active module with HEPA filters. A moulds assembly system allows the operator to change moulds easily. After the change-over there is a rapid cycle of sterilization with VHP before aseptic production is restarted.
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