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扎啤灌裝清洗自動線

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桶裝扎啤酒自動清洗灌裝線設計方案

KEG WASHING AND FILLING LINE WITH AUTOMATIC PASTEURIZER

DESIGN AND QUOTATION

 

一. 設備配套方案及能力設計:

全套設備由二條連體結構的清洗、灌裝線主機;一個主電氣控制箱;一套自動稱重及推出裝置;一套用于扎啤桶自動輸送的走鏈輸送系統及相關配套的蒸汽、CO2過濾器等組成。

設備按客戶需要以容積30L標準不銹鋼保溫桶為參照標準設計,按一條自動清洗、灌裝線60/小時能力設計。

A. Equipment matching scheme and design ability:

A full set of equipment is including two conjoined structure including of cleaning, filling line host, a main electric control box, a set of automatic weighing system,  a set of automatic conveyor system and related steam and CO2 filter and so on.

According to the customers' ans standard keg is 30L stainless steel keg as reference, an automatic cleaning, filling line capacity is 60 PCS/hour .

設備列表 ( Equipment list ):

序號

No.

名 稱

Name

規格型號

Specification

單位

Unit

數量

QTY

備注

Remark

1

清洗灌裝機

Keg Washing And Filling Line

60pcs/H  

Set

1

直線式

Straight-line

2

瞬時殺菌機

Pasteurizer

2000L/H

Set

1

 

3

緩沖罐

Butter tank

3000L

Set

 

配置:防負壓閥一套、防正壓安全系統3套、CIP一套

Configuration: a set of negative pressure valve, 3 sets of prevention positive pressure safety system,a set of CIP

4

自動稱重系統

Automatic weighing system

120pcs/H最大量程(MAX): 150KGS

Set

1

主要配件瑞士梅特勒-托利多

Main component: Mettler Toledo, Switzerland

5

自動輸送帶

Automatic conveyor system

120pcs/H

meter

6

不銹鋼輥筒式

 Stainless steel rollers

6

減速機

Reducer

 

PCS

3

 

7

過濾器

Filters

CO2

Set

2

 

8

過濾器

Filters

蒸汽

Steam

Set

1

 

9

自力式蒸汽減閥

Self-acting steam reducing valve

DN25

Set

2

 

10

現場安裝管道及閥門

Install pipes and valves in scene

DN32/DN40/DN80

Set

1

 

 

二. 設備基本結構及工作流程:(參考設備現場布局圖)

1. 設備結構:

清洗灌裝線采用U型擺放結構,進桶和出桶的方向保持平行。一套輸送走鏈、一套桶預洗、一臺桶外洗、一套預洗不合格推出裝置、一套自動稱重及不合格推出裝置、一套供桶內壁清洗用的CIP系統。設備總體呈U型擺放,進桶走鏈與平行擺放的清洗、灌裝線和出桶走鏈呈垂直結構,分別位于灌裝線的進桶和出桶位置。供桶內壁清洗用的CIP系統位于灌裝線結構的中間部分,以便于節省空間。清洗、灌裝線通過管路接口與供桶內壁清洗用的CIP系統和外部壓縮空氣、CO2、蒸汽、酒液等管路連接(現場連接)。

2.工作流程:

待清洗及灌裝的空桶通過人工方式擺放到進桶的輸送走鏈上(酒矛口向下),通過輸送走鏈輸送到清洗、灌裝線的入口位置;在程序控制下,清洗、灌裝線通過進桶、移桶裝置使桶移動到工位1的位置開始進行刷洗;工位1刷洗流程完畢后,移桶裝置動作,將桶從工位1移動到工位2,開始進行工位2的刷洗流程;同時移桶裝置動作時將下一個桶移動到工位1進行工位1的刷洗流程。通過每一次的移桶動作,使每個桶都按流程在工位1到工位6完成刷洗、殺菌、灌裝的過程。灌裝后的成品通過各線的移桶裝置推到出桶輸送走鏈上,再通過輸送走鏈輸送到稱重裝置上進行稱重;重量合格的產品通過輸送走鏈輸送到成品區域,重量不合格的產品在經過稱重推出裝置時推到重量不合格區域。

B. Structure and work procedure: (reference design drawing in scene)

1. Structure:

Clean the filling line by using the u-shaped structure, the keg inlet and outlet is kept parallel. A set of conveyor chain, a set of pre-wash, a set of outside washing, a set of prewashing unqualified roll-out devices, a set of automatic weighing and disqualified roll-out devices, a set of CIP system for the cleaning of the keg’s inner wall. The equipment is generally u-shaped, and the inlet conveyors and outlet conveyors  are vertical with keg filling and washing line respectively. The CIP system for cleaning the inner wall of the keg is located in the middle part of the filling part so as to save space. The washing and filling line is connected with the CIP system, external compressed air, CO2, steam, beer pipe and other pipe connections (site installations ) through the pipe interface and the cleaning of the inner wall of the keg.

2. Work procedure:

(1) Put keg up-down on the conveyor, keg will prepare working automatically.

(2) Keg will prepare working automatically move to station 1 begin washing.

(3) Keg will move to station 2 washing automatically, at the same time, next keg will move on station 1 to prepare washing.

(4) Keg will finished wash, sterilize and fill from station 1 to station 6 as the same way.

(5) Keg will move on the weighing system to check up to standard or not by the conveyor.

 

 

三、 各部分性能介紹:

1. 清洗、灌裝線主機:

(1)本機是啤酒桶裝容器專用清洗灌裝設備。本機配套一套清洗、灌裝頭裝置,可以通過互換方式適用井式酒矛和板式酒矛的不銹鋼扎啤桶的清洗及灌裝。

(2)本機采用全自動工作方式,自動完成桶的各工位轉移及各工位的清洗及灌裝,無需人員手動操作。

(3)配套有單獨清洗功能,只清洗不灌裝,可作預洗機使用。

(4)配套手動操作功能和報警顯示功能,便于設備的檢修和維護。

(5)實時顯示當前的工作狀態和工作步驟。

(6)適用于不同容量和標準范圍內桶型的扎啤桶。可適應桶高300-500mm;桶直徑300-450mm;桶酒矛上端距桶延上端距離小于22 mm

(7)機械傳動機構采用機械曲桿聯動方式,使設備運行平穩、可靠、定位準確,避免故障率的發生。

(8)設備配有自動壓力檢測,吹掃后殘液檢測,酒矛開啟檢測,殺菌溫度檢測功能,并帶有工位報警,相關工位報警后,下面工位均停止工作并停止灌裝,可保證灌裝酒理化指標的合格,避免酒的浪費。

(9)灌裝采用CO2備壓,保壓的低壓差全封閉灌裝方式,灌裝量采用進口流量計檢測,可根據不同容量桶設定不同的灌裝容量。并帶有桶的灌滿溢流檢測,可保證灌裝后酒的低沫、低耗,灌裝量準確,酒損可控制在1%以下。

(10)設備帶有自有CIP及酒管路CIP的刷洗功能,可保證酒管路及灌裝頭的衛生,使桶裝酒符合衛生標準。灌裝后的酒保持啤酒的原有口感、口味。

(11)設備灌裝采用體積灌裝方式,可通過觸摸屏設定和調整灌裝容量,并可進行誤差調節,可實時顯示灌裝桶數及升數。正常灌裝誤差可控制在0.2L

(12)設備隨機配套CO2過濾器、蒸汽過濾器及減壓閥等,保證成品酒的保質期。

(13)單條清洗、灌裝線設計能力為60/H30L標準),總能力為。

C. Performance introduction of each part:

1. Main part of Washing and filling line:

(1) This machine is a special cleaning and filling equipment for beer kegs. The machine is equipped with a set of cleaning and filling head, which can be change easily of A,S,D,G, M typer spear.

(2) The machine adopts fully automatic working mode, automatic completion of each station transfer and the cleaning and filling of each station, and no manual operation is required.

(3) There is a separate cleaning function, only cleaning and not filling, which can be used by pre-wash machine.

(4) Supporting manual operation and alarm display function for easy maintenance and maintenance of equipment.

(5) Real-time display of current work status and work procedures.

(6) The bucket of barrels is applicable to different capacity and standard range. It can adapt to the keg height 300-500mm; keg diameter 300-450mm; The upper end distance of the barrel extension is less than 22 mm.

(7) Mechanical driving mechanism adopts the linkage mode of mechanical crank, so that the equipment can run smoothly, reliably and accurately, so as to avoid the occurrence of failure rate.

(8) Device is equipped with automatic pressure detection, residual liquid detection after purging, wine spear open detection, sterilization temperature detection, alarm and location, the location after the alarm, the following location are to stop work and stop filling, can guarantee the physical and chemical indicators qualified filling wine, avoid the waste of alcohol.

(9) The filling is filled with CO2 backup pressure, and the pressure differential is sealed and filled. The filling volume is tested by imported flow meter, and different filling capacity can be set according to different capacity barrels. It can be used to ensure the low foam, low consumption, accurate filling quantity, and the alcohol loss can be controlled below 1%.

(10) The equipment has its own CIP and wine pipeline CIP cleaning function, which can guarantee the hygiene of the wine pipeline and the filling head, so that the wine can meet the hygienic standard. The wine after filling keeps the original taste and taste of beer.

(11) The filling method of the equipment can be set and adjusted by the touch screen to adjust the filling capacity, and can adjust the error, which can display the number of filling barrels and liters in real time. Normal filling error can be controlled at 0.2 L.

(12) The equipment is randomly matched with CO2 filter, steam filter and pressure-reducing valve to guarantee the expiration date of the finished wine.

(13) The design capacity of single cleaning and filling line is 60 PCS/H (30L), and the total capacity is.

 

 

設備參數 Equipment parameters

名稱

Name

技術參數

Technical Parameter

名稱

Name

技術參數

Technical Parameter

生產能力

Capacity

Single line 60PCS/H

堿水濃度

Caustic concentration

1.5%-2%

總功率

Total Power

3phases 6KW

水泵揚程

Pump head

38m

氣缸工作壓力

Cylinder Working Pressure

0.45~0.5Mpa

堿水溫度

Caustic Temperature

80~85

氣沖壓力

Air Blowing Pressure

0.25~0.3Mpa

熱水溫度

Hot Water Temperature

85~90

CO2吹掃備壓壓力

CO2  Pressure Prepare

0.2~0.25Mpa

空氣消耗量

Air Consumption

3m3/H

蒸汽壓力

Steam Pressure

0.5~0.7Mpa

CO2消耗量

CO2 Consumption

2m3/H

水泵工作電壓

Pump Working Power

AC380V/50Hz 3phases

自來水消耗量

City Water Consumption

1500L/H

控制系統電壓

Control System Power

DC24 V

蒸汽消耗量

Steam Consumption

2.5m3/H

保壓指數

Holding Index

0.1~0.15 Mpa

灌裝容量

Filliing Volume

10~50 L

酒管線壓力

Beer Pipe Pressure

0.18~0.22Mpa

酒損

Loss Ratio

1%

2.桶內壁清洗用的CIP系統:

(1)系統配套三個CIP水箱和三臺CIP水泵;分別為堿水、熱水、混合水。三臺水泵的最大揚程均為40-45米,配套自動恒壓閥供給清洗、灌裝線使用。

(2)堿水箱和熱水箱具有自動補水,自動加熱并恒溫功能,保證CIP液的工藝要求。

2. CIP system for cleaning of keg inner surface

(1)The system has three CIP tanks and three CIP pumps,water tanks is Caustic, hot water and rinse water. The maximum lift of each pump is 40-45 meters. The automatic constant pressure valve is provided to washing and filling line.

(2) Caustic tank and hot water tank have automatic filling water, automatic heating and keeping temperature function to ensure the process requirements of CIP liquid.

 

設備尺寸 Equipment Size

 

主機外型尺寸

Size of main part

L3990×W1060×H2300(M)

設備重量

Weight

1500KGS

CIP水箱容積

CIP tank volume

700L*3

 

60桶/小時標準配置表 Standard configuration sheet

序號

名  稱

型  號

數 量

廠 家

1

PLC CPU

S7-300 314

1個

西門子

Siemens

2

模塊

PLC modules

321、322

4個

西門子

Siemens

3

觸摸屏

Touch panel

KTP1200

1個

西門子

Siemens

4

電器

Electric appliance

斷路器、接觸器

Breaker、contactor

1套

施耐德

Schneider

5

溫控表

Temperature controller

SR3

3個

日本島電

shimaden

6

鉑電阻

Temperature sensor

PT100- 0.2級

3個

福光百特

7

壓力開關

Pressure measurement

PS30

5個

臺灣亞德客

Airtac

8

音叉液位開關

Vibronic point level detection

FTL20H-OTCJ2B

3個

德國E+H

Endress+Hauser

9

水泵

PUMP

CDLF2-4

2臺

南方泵業

CNP

10

水泵

PUMP

CDLF4-4

1臺

南方泵業

CNP

12

流量計

Flow meter

DN25

1個

德國寶德

Burkert

13

氣動閥

Pneumatic valve

DN15-DN32

30個

ESG

14

氣缸

Air cylinder

SC80

8個

臺灣亞德客

Airtac

15

框架,板料

Frame,

SUS304

 

國產優質

16

管路,管件

Pipes and Lines

SUS304

 

遠安

Yuanan

 

 

3.殺菌機(2000L/小時)

設備結構:

啤酒管路系統

由視鏡、啤酒入口閥、啤酒高壓泵、板式換熱器、保溫管段、流量調節閥、渦輪式流量計、出口氣動蝶閥、循環氣動換向閥等組成。

蒸汽管路系統

由蒸汽球閥、蒸汽減壓閥、蒸汽氣動調節閥、蒸汽換熱器等組成。

熱水管路系統

由加水閥、立式貯水罐、熱水泵、板式換熱器等組成。

冷劑管路系統

由過濾器、冷劑閥、冷劑泵、板式換熱器等組成。

儀表電控系統

顯示儀表有冷劑壓力表、啤酒電接點壓力表等。控制裝置由啤酒流量、殺菌溫度、冷卻溫度PLC及電器元件和指示燈等組成。

工作原理:

準備殺菌的冷啤酒經過高壓啤酒泵進入板式換熱器,被已完成殺菌的熱啤酒預加熱到65℃,再被85℃的熱水加熱到75℃,在保溫管段保溫30秒后達到巴氏殺菌單位25Pu值,然后再被預熱的冷啤酒降溫至12℃,最后進入冷卻系統被冷卻至2℃,進入緩沖罐準備灌裝。

操作時殺菌溫度低于工藝要求(設定為75)時,可自動進入循環狀態,當殺菌溫度升到75℃時延時1分鐘自動關閉循環閥,開啟出酒氣動蝶閥,保證殺菌質量。其它控制參數超出設定值時,設備報警并自動停車。

 

 

 

3.PASTEURIZER (2000L/H)

Pasteurizer structure:

Beer piping system

By sight glasses, beer high-pressure pump inlet valve, beer, plate heat exchanger, heat preservation pipe section, flow control valve, turbine flowmeter, exports pneumatic butterfly valve, pneumatic directional valve cycle, etc.

The steam piping system

Ball valve by steam, steam pressure reducing valve, pneumatic control valve, steam heat exchanger, etc.

Hot water piping system

By adding water valve, vertical storage tank, heat pump, heat exchanger, etc.

Refrigerant piping system

By the filters, cooling valve, cooling pump, heat exchanger, etc.

Electric control system of instrument

Display instrument refrigerant pressure gauge, beer electric contact pressure gauge, etc. Flow control device by beer, the sterilization temperature, cooling temperature, PLC and electrical components and lamp, etc.

Working principle:

Prepare sterilization cold beers after high pressure pump into the plate heat exchanger, have been completed per heated to 65 ℃ heat sterilization of beer, then by 85 ℃ hot water heated to 75 ℃, the heat preservation thermal insulation pipe section after 30 seconds to 25 pu pasteurization unit value, and then be cooled to 12 ℃ preheat the cold beer, and finally into the cooling system is cooled to 2 ℃, into the buffer tank for filling.

Operation sterilization temperature is lower than the technical requirements (set at 75 ℃), can be automatically entered into circulation state, when sterilization temperature up to 75 ℃ delay 1 minute closed automatically circulating valve, pneumatic butterfly valve to open out the wine, ensure the quality of sterilization. Than other control parameters setting, alarm and automatically stop equipment.

 

 

 

2000L/H 標準配置表 Standard configuration sheet

序號

名  稱

型  號

數 量

廠 家

1

PLC CPU

S7-200

1個

西門子

Siemens

2

PLC module

EM221\223

2個

西門子

Siemens

3

觸摸屏

touch panel

SMART700IE

1個

西門子

Siemens

4

電器

electric appliance

斷路器、接觸器

Breaker、contactor

1套

施耐德

Schneider

5

流量計

flowmeter

DIN11850R2 DN25

1個

寶德

Burkert

6

鉑電阻

PT100- 0.2級

2個

福光百特

7

電接點壓力表

1.6MPa

1個

沈陽儀表廠

8

水泵

pump

CDLF2-6

1臺

南方泵業

CNP

9

水泵

pump

CHL2-30

1臺

南方泵業

CNP

10

水泵

pump

CHL4-30

1臺

南方泵業

CNP

11

氣動角座調節閥

Pneumatic Angle seat regulating valve

514 25D+1436

1個

德國蓋米

GEMuGebr. Muller

 

氣動角座調節閥

Pneumatic Angle seat regulating valve

514 15D+1436

1個

德國蓋米

GEMuGebr. Muller

12

氣動薄膜調節閥

Pneumatic diaphragm regulating valve

687 20D+1436

1個

德國蓋米

GEMu Gebr. Muller

13

氣動蝶閥

Pneumatic Butterfly Valve

DN32

2個

遠安

Yuanan

14

氣動換向閥

Air Operated Reversing Valve

DN32

1個

遠安

Yuanan

15

框架,板料

304不銹鋼

 

國產優質

16

管路,管件

304不銹鋼

 

遠安

Yuanan

17

板式換熱器

V-series plate heat exchanger

V13-316L

1套

中法合資維克斯

VIEX

18

板式換熱器

V-series plate heat exchanger

V4-316L

1套

中法合資維克斯

VIEX

 

 

4.緩沖罐(3000L無脖法蘭錐體罐)

  罐體材質SUS304.

通體壁厚不小于4mm .

內表面鏡面拋光,光潔度0.1μm.

罐頂要求配置防負壓裝置、防正壓0.3MPa安全裝置、罐內CIP閥、罐內旋轉清洗球、CO2備壓閥、壓縮空氣吹掃閥、排氣閥、液位CIP閥及電接點壓力表。

罐底要求配置DN50衛生級蝶閥。排放1、進酒1、進酒2CIPCIP回、排放、出酒及CIP回泵

控制系統配置手動/自動、CIPCO2、壓縮空氣、液位清洗、CIP回泵。

4. Buffer tank (3000 L without neck flange cone)

Container materials SUS304.

The body wall thickness is not less than 4mm.

The inner surface mirror polishing, arrive at 0.1 μm .

Roof requirements to prevent negative pressure device, the positive pressure 0.3 MPa safety device, tank CIP for rotary cleaning ball valve, tank, CO2 pressure valve, compressed air purge valve, exhaust valve, liquid level CIP valve and electric contact pressure gauge.

The bottom of the tank is required to configure the DN50 sanitary butterfly valve. 1. Enter wine, CIP, CIP, CIP, CIP, wine and CIP back pump

The control system is equipped with manual/automatic, CIP, CO2, compressed air, liquid level cleaning, CIP return pump.

5.稱重系統

(1)稱重系統是在一臺平板式電子秤的上方配套走鏈輸送系統,通過走鏈的輸送使要稱重的桶運行到電子稱的上方,通過走鏈暫停后的時間內完成自動的稱重過程。

(2)稱重后的桶是否達到重量標準是利用桶的實際稱重值和稱重儀表的設定值來比較判定;實際稱重值大于或等于設定值時視為合格。

(3)稱重的最大量程為150KG

(4)稱重后的桶是否合格由控制系統判定并記憶,當不合格的桶輸送到推出裝置上時,推出裝置自動動作將桶推到不合格區域;合格的桶推出裝置不動作,通過輸送走鏈直接輸送到成品區域。

5. Weighing system

(1) Weighing system is in a plate type electronic scale above supporting chain conveyor system, go through the chain transmission to run to the electronic weighing barrel according to the above, go through the chain suspension after complete automatic weighing process.

(2) Whether the bucket meets the weight standard is to use the actual weighing value of the bucket and the set value of the weighing instrument to compare the judgment; The actual weighing value is considered qualified if the value is greater than or equal to the set value.

(3) The maximum weight range is 150KGS.

(4) Whether the bucket qualified after weighing is determined by the control system and memory, when the unqualified bucket is delivered to the launch device, the device automatically pushes the bucket to the unqualified area; The qualified drums are not moved, and are transported directly to the finished area through the conveyor chain.

配置表Standard configuration sheet:

序號

No.

名  稱

Name

型  號

Type

數 量

QTY

廠 家

Manufacturer

1

電子秤

Weighing system

TCS-150

1個

METTLER TOLEDO

2

控制器

Controller

IND131

1個

METTLER TOLEDO

3

走鏈

Conveyor

 

1套

自制

4

光電開關

Photoelectric Switch

BR400-DDT-P

3個

AUTONICS

5

氣缸

Cylinder

SC80-500

1個

AIRTAC

6

電機減速機

Motor Reducer

0.4KW

1個

 

 

6.輸送走鏈:

(1)全部進出桶走鏈均采用不銹鋼鏈輥式走鏈,配套進出桶擋桶裝置,根據三條線的啟停狀態及計數機構同時供給三條線的進桶和桶的輸出。

(2)配套光電開關及可擋桶器,可根據桶的直徑不同對光電開關進行調節,使桶居中運行,以便于適合不同桶型。

6. Conveyor chain:

(1) All inlet and outlet the conveyor chain adopt stainless steel chain roller chain, form a complete set of inlet and outlet blocking device, according to three lines of start-stop condition and counting mechanism at the same time supply three line into the keg and the keg of the output.

(2) The auxiliary photoelectric switch and the keg can be used to adjust the photoelectric switch according to the diameter of the keg, so that the keg can operate in the middle of the conveyor, so that it can be suitable for different kegs.

四.主機CIP刷洗方案:

清洗、灌裝線主機的灌裝頭及酒管路在每次生產前后均需要做CIP刷洗,正常使用80-85度的熱堿水和熱水。本設備不另外配套主機自身的CIP刷洗系統,CIP由用戶自行配套。CIP通過酒管路進入灌裝頭內,清洗酒管路和灌裝頭及相關管路。設備配套CIP的刷洗程序,在CIP程序模式下用戶可進行CIP刷洗。因為設備刷洗所耗用CIP液數量較少,因此不配套堿回收管路,刷洗后的堿水及熱水均排放處理。如果用戶需要進行堿回收請提前說明。

D. Host CIP cleaning scheme

The filling head and pipeline of the washing and filling line are required to be cleaned by CIP before and after each production, normally using 80-85 degrees of hot alkali water and hot water. The device does not have the CIP cleaning system of the host itself, CIP is provided by the user. CIP enters the filling head through the wine line, cleaning the wine pipeline and filling head and related pipeline. With CIP, the user can be scrubbed by CIP in CIP program mode. Because of the small amount of CIP fluid used in the cleaning of equipment, no alkali recovery line is used, and the alkaline water and hot water are discharged after washing. If the user needs to perform alkali recovery, please specify in advance.

五. 設備配置方案:

設備框架、管路、閥門、水箱等均采用標準SUS304材質;電器部件、水泵、檢測元件、傳感器等均采用高檔配置。

E. Equipment configuration scheme:

The equipment frame, pipeline, valve and water tank are all made of standard SUS304. Electrical components, water pumps, detection components, sensors are all in high - grade configuration.

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青島三德啤酒設備有限公司
聯系人:王經理
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