Electronic Dairy Rotary Filler
Based on the concept of modular systems, the range of Hema Quatro fillers have been designed to respond to the specific demands of the markets they work with.
Conclusive benefits
- Electronic filling technology providing unmatched filling accuracy for your dairy product
- The hygienic way in which dairy products are introduced means a clean machine and reduces the possibility of product contamination. Each filler head has its own feeder pipe connected to 3A standard sanitary fittings, allowing each filling valve to act independently.
- A common frame designed for optimal hygiene
- Technical design providing adaptability between weight filling and mass flow filling.
- Optimal filling capacity for the 2 technologies in terms of production speed, efficiency and optimisation of the surface utilised.
- A common frame with several possible structures, allowing for the inclusion of numerous environmental options.
The Quatro Sensi filler series is dedicated to the sensitive dairy products market and it benefits from Hema’s many years’ experience, particularly in the filling of milk and liquid dairy products for leading international groups.
Whatever the sensitivity of these dairy products is, we are very attentive to Food Safety.
Fresh, pasteurised or extended shelf-life (ESL), our range of filling and capping machines has been designed to meet your specific needs.
At the heart of sensitive products
The Filling method is carefully chosen to match the intrinsic characteristics of your dairy product: its type (e.g. liquid, thick, with or without particulates), what needs to be protected (flavour, vitamins, colour, etc.), its shelf-life (short or long), its sensitivity to external elements (temperature, oxygen). It is a complex equation between relative acidity (pH), the presence of nutrients, presence of O2, sugar content, preserving agents, artificial colourings, stabilisers, which all have an impact on the conservation and bacteriological quality of your dairy product.
Our deep understanding of our customers’ dairy product specifications relating to filling has led us to put in place 4 environmental filling families.
They mainly depend on the dairy product (weak or high level of acidity), the distribution circuit (cold chain or room temperature) and the expected shelf life of the product.
We define them as follows: Classic, Select, ESL 1 or ESL2. They are categorised by the combination used within the following two criteria:
- internal levels of cleaning and sanitation of your product circuits;
- external levels of aeraulic protection for the filling and capping group, to guarantee the production conditions that meet your products’ specifications
For example, fresh milk distributed through the cold chain can be filled by the Classic or Select process and does not require container treatment. Whereas ESL dairy products require clean or ultra-clean treatment, including decontamination of the bottle and cap. Air-filtering through a Hepa filter is provided, thanks to an air overpressure system including adjustable hygrometry and temperature control.
Our fillers meet the highest hygiene standards. They are 3A certified and we are a member of EHEDG.
Quatro Sensi filler is available in Monobloc configuration with capper or thermosealer. Our filler can also be synchronised to a neck trimmer or a rinser. Combi configuration associates blowing, filling and capping for PET bottles
We offer 2 dairy filling technologies: WEIGHT – MASS FLOW
Hygienic conception for ESL configuration
Hema Quatro Sensi Monobloc rinser, filler, capper
Technologies in Dairy Filling
Select the best technology for your dairy filler:
A simple principle: one weight, one measurement. Weight technology is the ideal solution for slightly viscous liquid products.
Special Features
Filling
15 to 88 heads
Capping
5 to 22 heads
Volume
80 ml to 5 litres
Containers
PET, HDPE or glass bottles
Speed
6 000 to 40 000 bph
Main Benefits
By means of individually controlling the net weight of a dairy product, every bottle that enters and exits the filling machine is checked. The micro-processor in the electronic load cell pilots the filling according to the weight of the bottle.
The filling machine is equipped with a new DVS series weight detector, provided by our partner, Scaime. It is made of 100 % stainless steel and is the only electronically integrated EHEDG-certified detector. Its sturdy design meets several norm requirements, including IP69K
For drinking yoghurts and other dairy acidic products, the Essential filling valve (We) meets the highest hygiene requirements.
For more sensitive utilisations, Quatro Sensi is equipped with a magnetic filling valve (Wg). This valve guarantees perfect leak-proof between the product circuit and the environment, without using a membrane or rod.
Unrivalled filling accuracy
The highly precise piloting of the filling regulator (2 different speeds: high and low) obtains optimal filling accuracy, according to the format of the bottle, the bottle-neck space, the temperature and type of oil. We guarantee a standard deviation of less than 0.5 grams for 1 litre.
Dairy filling flexibility
Thanks to its patented double flap valve, Quatro Sensi makes it possible to fill volumes from 80 ml to 5 litres at optimal speeds and without changing nozzles.
Environment and accessibility
The filler frame is in stainless steel and slopped to make it easy to clean (no adhesive areas).
Its wide doors allow easy access to the entire machine. An angular collecting trough recuperates the product at the end of production. Cleaning of the product circuit is done in a closed circuit.
Capping turret
The capping turret in a clean and ultra clean configuration meets Classic, Select and ESL level hygiene requirements.
Quick tool changeovers
The different coloured tools specific to each bottle format are available on the filling and capping turrets. They make tool identification easy. Without the need for special tools, the rapid fixing and indexing systems make it easy for the operator to set up. This means that time taken for tool changeovers is optimised.
Productivity optimisation
Hema Quatro Sensi is equipped with a reduced-sized hopper and remote nozzles, ensuring minimal product loss between recipe changes.
Complete dairy packaging lines
Discover our complete lines solutions dedicated to liquid dairy products:
Essential filling head (We)
Magnetic filling head (type Wg)
The principle: one speed, one measurement. This type of doser measures a mass which is dosed using a Coriolis sensor. Moreover, this type of sensor measures the dairy product density, temperature and speed.
A PLC system pilots the filling, according to the measurement taken by the mass-flow detector
Special Features
Filling
15 to 60 heads
Capping
5 to 22 heads
Volume
80 ml to 5 litres
Containers
PET, HDPE or glass bottles
Speed
4 500 to 40 000 bph
Main Benefits
The mass-flow filler is equipped with the latest checking technology and delivers clean dairy product filling. The environment is hygienic, and the filling is precise, whilst keeping maintenance down to a minimum.
Unrivalled filling accuracy
Filling is extremely acurate, even at high speeds. Thanks to specially adapted nozzles, containers are filled up without drips or frothing. This filling technology guarantees a standard deviation of less than 0.5 grams for 1 litre.
Environment and accessibility
The filler frame is in stainless steel and slopped to make it easy to clean (no adhesive areas).
Its wide doors allow easy access to the entire machine. An angular collecting trough recuperates the product at the end of production. Cleaning of the product circuit is done in a closed circuit.
Capping Turret
The capping turret in a clean and ultra clean configuration meets Classic, Select and ESL level hygiene requirements for your dairy products.
Productivity optimisation
Our filler is equipped with a reduced-sized hopper and remote nozzles, ensuring minimal product loss between recipe changes.
Quick tool changeovers
The different coloured tools specific to each bottle format are available on the filling and capping turrets. They make tool identification easy. Without the need for special tools, the rapid fixing and indexing systems make it easy for the operator to set up. This means that time taken for tool changeovers is optimised.
Complete dairy packaging lines
Discover our complete lines solutions dedicated to liquid dairy products
Mass Flow technology
Options & peripheral equipment
For an optimal dairy production, we offer options and peripheral solutions:
Decontamination of containers and caps
In ESL configuration, the decontamination of PET, PEHD or glass bottles and caps is done by pulsed light or wet or dry decontamination.
Cleaning and Sanitation in Place
Either an angular collecting trough or dummy bottles (weight technology only) are placed to recuperate the product at the end of the production line. The « dummy bottles » procedure enables a closed-circuit CIP to take place, in addition to steam sanitation of the machine parts in contact with the product, at temperatures up to 125°C.
Automated CIP, COP, SIP cleaning and sanitation cycles:
- Quatro Sensi can be linked up to the cleaning station for distributing or collecting cleaning products (provided by customer or ourselves); different automated cycle options are available, according to the process or product specifications.
- Cleaning arms and turbo disks ensure perfect cleaning of the environment around the filling turret (turret exterior, transfer tool, cabin interior, etc.).
- Possibility of foaming station
- Sanitation of the product circuit (SIP) is carried out by steam-cleaning at temperatures between 95° C and 125°C according to specifications.
Control – Ejection
Any faulty, badly-filled or capped containers are ejected from the production line.
Smart cap dispensers and feeding systems
Various options are proposed:
Elevators that stock and transport the caps to the dispenser.
Elevator-Orientators select the direction and transport caps at high speed within the same machine. They replace the elevator-distributor duo.
Cap buffer is installed on the filling and capping monobloc in the Combi configuration. It receives the directed caps and feeds the cap turret with the caps.
