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Various information proves that the beer market at home and abroad is about to enter a hot period of sales of plastic bottles including small-capacity bottled beer. According to reports, in 2005, PET bottled beer will reach 3.5% of the total global beer sales.
Ideal filling: isometric filling system
Under normal circumstances, beer is filled into a plastic bottle through a bottle filling and filling machine. The rinsing process first removes residual material from the plastic bottle blown by the blow molding machine. Since the oxygen in the wash water is always saturated, each drop of residual moisture adds oxygen to the beer. It is therefore recommended to use an electro-controlled two-channel bottle washer to rinse the plastic bottle and then dry it with sterile air.
In terms of the filling process, the trend of using an isometric filling system equipped with an inductive flow meter is becoming increasingly apparent. This process is ideal for containers of the precise size of plastic bottles. For aseptic polyester bottle filling processes, Krones must use this isometric filling system. Because it uses a long tube filling system, it is gently filled under the surface of the liquid level, and before the capping, the gas in the ring cylinder is used for rinsing, and then the carbon dioxide is discharged in a clean gas passage. Prepare for pressure so that very good oxygen levels can be maintained. The air inside the polyester bottle will be discharged from the bottom up and the outside, and the effect is very good. Since the valve does not have a spring device, a very hygienic design is formed.
The Krones VODM-L-PET filling system first uses a bottled jet. Here Krones avoids the use of a dynamic seal, but uses a folded air bag valve for static sealing, followed by back pressure with clean gas before slow filling and fast filling. Here you can also take a small bottle of slow irrigation, a large bottle of quick irrigation. After the filling is completed, wait for a certain static time, let the large bubbles float on the liquid surface, the plastic bottle is released, and the bottle is immediately drained after the bottle is lowered. The CIP cleaning procedure is best used in this filling system. The CIP cleaning program can be set by an electric control system. This program guarantees optimal flow conditions.
Advantages and disadvantages of plastic bottles
Plastic bottles filled with beer have both advantages and disadvantages. The advantages are obvious in light weight, not easy to break, flexible in design, highly transparent, and can create accurate dimensions. However, the plastic bottle cannot be completely vacuumed in the filling machine, so its airtightness is not good. Since atmospheric pressure plays a major role in gas exchange, oxygen will penetrate into the plastic bottle (the oxygen content of the product should be reduced as much as possible) and release carbon dioxide.
Plastic bottles should not be overheated, which means that plastic bottles cannot be pasteurized. Its head has a limited compressive strength, which affects the choice of cap. When it is pressurized and heated, its volume changes, and the bottom of the bottle rises and the bottle easily falls over. Plastic bottles are generally more dimensionally accurate than glass bottles, but they are not standard containers at the specified angle. Ambient temperature, light, and handling during transportation can affect plastic bottles. Other factors include the raw materials used to make the plastic bottles, the selected design and the blowing process and the shrinkage of the bottles.
Cap type
The choice of bottle cap type has a great influence on the air in the bottle neck, the total amount of oxygen and the shelf life of the beer. A variety of different cork plastic caps, aluminum caps, crown caps, screw caps and pre-sealing caps are available on the market. These caps have their own advantages and disadvantages.
Pre-sealing cap
There are two ways to choose from. One is that after the high-pressure sprinkling, the pre-sealing cover is separately placed on the bottle mouth, and then the air is blown by the thread. After checking the position of the pre-sealing cover, the original screw cap is sealed.
The second is a built-in pre-capped screw cap. When the cap is screwed on, the gasket to be built is pressed against the bottle mouth, then threaded, and the cap is tightened.
Difference between oxygenation in long tube filling machine and short tube filling machine
Oxygenation is an important indicator when filling beer into PET or plastic bottles. In order to compare the various filling systems and cap types, the following theoretical calculations are listed. Of course, these theoretical values ​​may deviate from the actual situation. The numerical calculation is based on 500 ml/bottle, a carbon dioxide content of 5.5 g/l, and a filling temperature of 12 °C. Assuming that the initial oxygen content in the beer is 0.05 mg/l (when the bottle is rinsed), the purity of the carbon dioxide inside the bottle is assumed to be 96% to 98% (with flushing water).
The difference between the long tube machine and the short tube machine is that in the short tube filling machine, the purity of the carbon dioxide in the rinse bottle is 95%, and in the long tube filling machine, the purity of the carbon dioxide is 98%, and the oxygenation amount is The short tube filling machine is 0.08 mg/L, while the long tube machine is 0.03 mg/L. The latter case assumes the use of a VODM-L-PET filling machine with a pure CO2 backup. After the beer was injected into the bottle by the high pressure of the two filling machines, the air content in the bottleneck space was 0.35 mg/per bottle.
When using a crown cap, a screw cap or a cap with a pre-sealing cap, the total amount of oxygen is about 0.18 mg/l (according to the Uhlig & Vilacha law of Urich and Vera).
In the other case, if an aluminum cap is used, the total amount of air in the bottle seal of about 10.5 ml must be considered. However, it is also estimated that in an extremely unfavorable situation, 30% of the total air is pressed into the bottle. The remaining will leak along the thread, resulting in an actual new air volume of 3.15 ml.
This is even more pronounced when using a plastic cap without a pre-sealing. Since the plastic cap is the opposite of the aluminum cap, the cap is threaded and the gap between the cap thread and the cap thread is small, and it is estimated that only half of the air leaks through the thread. Therefore, in the worst case, an increase of 5.25 ml of air is added. According to this point of view, a cap with a pre-sealing, a screw cap or a crown cap should be used as much as possible.
Relationship between total oxygen content and bottle volume and cap type
From a series of tests, Krones compared the oxygenation of a 500 ml glass bottle with a crown cap and a 500 ml polyester bottle with a plastic screw cap: the oxygen content in the liquid (unit: mg / liter), the amount of oxygen in the neck space (unit: mg / liter) and total oxygen (oxygen total referred to as TPO, unit: mg / liter). The amount of oxygen flowing from the sake tank is 0.05 mg/L. By comparison, it can be clearly seen that there is a great difference between the glass bottle and the polyester bottle, wherein the pressure value of the oxygen content from the inside of the bottle neck is the highest in the polyester bottle.
Since the pressure in the bottleneck is related to the amount of filling, the size of the bottle is inversely proportional to the value, and the larger the bottle, the better.
Regardless of the market demand, in order to maintain the pure taste of the filling, these process factors will have an impact on the selection of the filling bottle and its cap.
Krones beer plastic bottle filling analysis