This valve is suitable for bottling still, sparkling and champagne products.
All the operating parameters:
- vacuum in bottle
- working pressure (from 0 to 8 bar)
- filling level (from 25 to 100 mm)
- de-gassing procedure are set on the control panel and can be changed with no manual intervention.
Hence, it is possible to quickly switch from one product to another. Bottling can be carried out under optimal conditions since oxidation is minimized and maximum sterility is guaranteed.
2. Level adjustment
The level can be adjusted in an automatic and centralized way, with a 25 to 100 mm adjustment range from the rim, with no manual intervention. Filling heights can be adjusted while the machine is operating. The valves have been designed to ensure precise filling height and tolerance is reduced to 0.5 mm by using the automatic leveling device.
3. Structure with double tube with lower closing
The filling and return gas tubes are closed when the required filling height is nearly reached, thus ensuring precise filling heights even without using the auto-leveling device. However, it is recommended that the auto-leveling device be used as it significantly reduces the quantity of product contained in the gas return tube before the beginning of the next filling cycle. If concerned about the return to tank of this minimum amount of product, E2 should be chosen so as to offer a better solution with gas return to a separate tank.
This structure brings remarkable advantages during the de-gassing phase since the perturbation caused by the de-gassing of the product in the gas return tube is completely eliminated. This is significant for the production of champagne–type wines.
4. Automatic dummy bottle
All the dummy bottles on the machine are automatically and simultaneously positioned with no manual intervention (for monoblocs with 20 spouts or more).
The dummy bottles optimize sterilization because the drain pipe can be opened or closed according to the circuit that needs to be washed. GAI’s dummy bottle is under specific patent.
5. Secure sterilizating cycle
The electro-pneumatically actuated valves, together with the dummy bottles with discharge circuit, guarantee effective and well defined sterilizing cycles.
The process improves sterilization, but also ensures for it to be securely carried out on any circuit on the filler.
The machines are linked to an automatic CIP system and the sterilizing cycle is carried out without the operator being present, thus improving the plant production timing.
6. Operating cycleiteration
The filling cycle, managed with timing phases, ensures maximum repeatability. Thus, the operating cycle is not affected by speed variations on the production line. This time management improves operating phases. The operating cycle may be personalized according to the type of product to be bottled, thus enhancing work quality as well as productivity. Timing is determined in 1000th of a second and repeatability is around 100th of a second.
7. Bottle detection
The proximity sensor on the edge of every spout is able to detect the presence of the bottle and enables the filling cycle to be started exactly when the bottle is held on the cone. This occurs without waiting for the bottle-lifting piston having completed its stroke as it happens in the traditional pressure fillers. Thus, the proximity sensor ensures proper operation and filler productivity.
8. Pressure transducer
The pressure transducer, on the edge of every spout, allows to check the bottle pressure step by step so as to control that the filling cycle is carried out correctly and to detect any anomalies or malfunctions. These controls allow to detect:
- top seal unscrewing
- insufficient vacuum degree
- exploded bottle or missing seal on the cone
- pressure trend during de-gassing.
Moreover, it is possible to check the efficiency of every single filling valve.
9. Four electro-pneumatic valve structure
Four electro-pneumatic valves are used to separately control the following circuits:
- 1. vacuum
- 2. tank gas
- 3. auto-leveling
- 4. de-gassing.
In comparison with the systems that use three valves only, the tank gas valve enables pressure compensation in bottle without using the return gas tube (it avoids sprinkling product residues inside the bottle) and without using “new” gas per each bottle.
The vacuum valve, at the bottom of the valve body duct, automatically “cleans” it every time a filling cycle takes place. The electro-pneumatic valves and the in-feed pipes placed near the filling spouts minimize the pipe volumes, thus reducing gas consumption, increasing productivity and ensuring an easy and proper filler sterilization.
10. Format saving
The filling cycle can be set by using the control panel and it does not require any manual intervention on the filler. Saving cycles and recalling them simplify and speed up the format changing operation. This guarantees a more uniform production.
Gas return to separated tank
With the E2 HP system the gas-return line is connected to a secondary collection tank P2.
This tank is pressurized at the same level as the filler bowl P1. Any drops of liquid that remain in the gas-return line C after completion of the filling operation are collected in the secondary tank L2 rather than returned to the filler bowl L1.
By using the auto-leveling system, liquid in C goes to L2, instead of returning back to L1.
The advantages are:
1. Reduced oxygen pick-up. Drops coming from C, that have been in contact with ambient/bottle gas, and are possibly lightly oxidized can be omitted.
2. Improved aseptic conditions. Drops coming from C, that may have been in contact with the bottle, and consequently at risk of contamination are removed. Approximately 5 cm. of wine per bottle will be returned to the secondary tank L2. The operator can decide if he wishes to reintroduce this quantity back to the filler bowl.
42000 E LP
Light pressure valve
The 42000 E LP valve is similar to the 42000 E HP one but it has no de-gassing circuit. This valve is provided with vacuum circuit, tank gas and auto-levelling device.
This valve has been designed for still or hardly sparkling wines (max 1 CO2/liter gram).
In this case, pressure goes from 0 to 1 bar.
Compared to traditional gravity or light vacuum valves, this valve brings the following advantages:
1. FLEXIBLE OPERATION. All the operating parameters –vacuum in bottle - working pressure (from 0 to 1 bar) - filling level (from 25 to 100 mm from the top of the mouth) are set on the control panel and can be changed with no manual intervention. Bottling can be carried out under optimal conditions since oxidation is minimized and maximum sterility is guaranteed.
2. LIGHT PRESSURE of the tank. It ensures no contamination caused by external elements.
3. Automatic and centralized LEVEL ADJUSTMENT with a 25 to 100 mm adjustment range from the top of the mouth with no manual intervention.
4. DOUBLE TUBE STRUCTURE WITH LOWER CLOSING. It ensures precise filling level and no dripping.
5. AUTOMATIC DUMMY BOTTLE. From 20 spouts onwards, dummy bottles are automatically placed. The dummy bottle improves sterilization because the drain pipe can be opened or closed according to the circuit that needs to be washed.
6. SECURE STERILIZATION CYCLE. The electro-pneumatically actuated valves, together with the dummy bottles with discharge circuit, guarantee effective and well defined sterilizing cycles.
7. OPERATING CYCLE REPEATABILITY.
The filling cycle, managed with timing phases, ensures maximum repeatability. Thus, the operating cycle is not affected by speed variations on the production line.
8. BOTTLE DETECTION. The proximity sensor on the edge of every spout is able to detect the presence of the bottle and enables the filling cycle to be started exactly when the bottle is held on the cone.
9. PRESSURE TRANSDUCER. It allows to check the vacuum degree in every bottle.
10. FORMAT SAVING. Saving cycles and recalling them simplify and speed up the format changing operation. This guarantees a more uniform production.
The roof basement is the ideal choice because all the upper surfaces are slanted toward the perimeter collection channel, there are no points where fl uids can stagnate and all the washing fl uids quickly drain. It is therefore easier to clean the machine. The entire structure is made of AISI304 stainless steel. The lower plate is a 15 to 20 mm thick single piece sized up to 3,000 x 6,000 mm. The cylinders holding the monobloc turrets in position are welded onto the frame. The upper section (skin) is a 5 mm thick glazed AISI304 stainless steel sheet that links the lower part to the turret basements. The whole struc- ture is rigid and reasonably light. All the upper and lower connections are NC machine-tool worked, they are therefore extremely precise. These parts are all produced in-house, which proves our labor force great fl exibility and our state-of-the-art equipment.