In order to redefine the boundaries of flexibility, Krones initiated the concept study of “on-demand fillingâ€.
“On-demand filling†represents a super-flexible production line that can be perfectly transformed with the push of a button:
Different filling methods
Personalized decoration
Carrying a personal RFID chip
Form a mixing tray directly in the production line
Personalized filling without dressing
The core element is a newly developed filling valve. It presses the bottle against the valve and the filling liquid flows down the wall of the bottle. So far, everything is still a regular step. The difference between this filling valve and other filling valves is their extraordinary diversity. It obtains the filling liquid through a main pipe and up to four auxiliary pipes, each of which can be separately fed. Depending on the application purpose of the filling machine, three completely different advantages can be brought:
No mixing machine
Soft drinks and other mixed beverages can be prepared directly in the filling machine: water enters the filling valve through the main pipe, and each flavor component is fed through the secondary pipe at a suitable flow rate. Therefore, it is no longer necessary to carry out the beverage mixing in the front mixer, and only the necessary pretreatment of the water and flavor components is required.
Product conversion does not need to be changed
Similarly, different finished syrups can be fed through the secondary tubes of the valve. In this way, different fillings can be accessed and closed without the need for a changeover. There is no longer a need for a cumbersome flushing process because the main channel flows in water regardless of the production of any product. The syrup flows into the machine through a separate line until it is added before filling. The new filling valve is equipped with a unique sealing method that completely eliminates the risk of odor.
Recipe customization
For all users who want to personalize their products to the limit, the system also has another option: a personalized combination of different inclusions – which can form a true one-piece batch. In this way, different components can be prepared through the secondary tube of the filling valve, and the precise beverage component can be determined individually for each bottle. “We are here mainly targeting high-end products and luxury products for branded goods manufacturers,†explains Stefan Pöschl, head of technology development at Krones. “For example, the formula for sports drinks and medical drinks is precisely adjusted according to the needs and preferences of consumers.â€
There is no problem with the obligation to inform the inclusion of substances: what kind of formula the consumer ultimately takes in his hand can be marked on each bottle by direct printing.
Mixing trays do not need to be shipped separately
How to implement the “on-demand filling†principle in a set of filling equipment requires consideration of many factors, especially the characteristics of each company. The concept study of the field test at this exhibition follows the principle of maximum flexibility and includes the following:
a filling station
a direct print module
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