Winegrowers Supplies  -  Counter-pressure (Isobaric) bottle fillers

A counter-pressure filler is necessary for bottling already carbonated drinks, such as beer, Sparkling cider or wine.

For large kegs (10 to 50 litres) a separate dedicated keg filler is necessary.

The drink will already be stored under pressure, so there is no need for a pump.

To avoid excess foaming the temperature of the liquid (when inside the filler's header tank) should be between - 3 C and + 4 C.

    RZ: semi-automatic Isobaric fillers:  delivery time about 8 weeks from order:-
    shown with optional RLC1 crown capper attached, 6950 Euros extra.

RZ-4: 4 nozzles, 10,690 Euros + 2120 Euros extra for optional pre-evacuation system.
Output is about 300 x 75cl bottles/hour. The output depends on the type of liquid, its temperature, pressure and if the pre-evacuation is single or double.
         1800 mm x 700 mm x 2100 mmH, 250 kilos.

RZ-6: 6 nozzles, 15,240 Euros + 2120 Euros extra for optional pre-evacuation system.
         2200 mm x 700 mm x 2100 mmH, 300 kilos.

RZ-2: 2 nozzles, 7,050 Euros

Option of bottle pre-rinser, 1190 Euros extra.

https://www.youtube.com/watch?v=PR-J8nUCYlc shows an RZ-4 in use, a demonstration of filling beer at room temperature without being chilled. Filling is even better when the drink has been chilled to 4 C or lower.

A compressed air supply is required, to be connected to the filler, the air consumption (RZ-4) is about 55 litres/min.

The pressure in the internal header tank of the filler must be set to about 0.2 bar higher than that in the storage tank. The header tank has a safety valve set to release at 5 bar. The tank is tested up to 7 bar.

The header tank has a capacity to hold about 20 litres of drink. Minimum and maximum level probes cause the inlet to open and close, in conjunction with the CO2, to stop the flow of CO2 or vent CO2 out and allow the drink to enter the tank up to the maximum level.

The bottle filling nozzle-valves, in addition to filling hole and central level (straws) have 3 holes:-
  the first for pre-evacuation,
  the second for the injection of CO2 from the cylinder,
  the third for the phase of degassing.
All of these are normally closed, until they are opened by manually switching pneumatic levers.
The pre-evacuation is made with a vacuum pump.

The filler processes all bottles simultaneously; it is necessary to have a bottle under each nozzle.

First pre-evacuation:
Switching the first pneumatic control lever creates a de-pressurising in all 4 bottles simultaneously, by means of the first hole of the valves. This allows most of the air contained inside the bottles to be sucked out.

Injection:
Switching the second lever opens the duct of inert gas from the cylinder to the second hole of the valves, which, because of the greater specific gravity, has the function of concentrating in part of the neck the remainder of the air present in the bottles.

Second pre-evacuation:
The second phase of pre evacuation has the same function as the first but allows removal of the remaining part of the air present in the bottles. This second pre-evacuation allows a high level of hygiene and hence conservation of the drink to be bottled.

Pressurisation (compensates for tank and bottles):
By means of the fourth lever, the pressure in the filler tank is transferred into the bottles.

Filling:
By means of the mechanical action of the spring, the valve is opened and allows the liquid to flow inside the bottles. With appropriate baffles, the drink flows as a film around the walls. Filling stops when the drink reaches the level tube (different length tubes are available depending on the fill-height of the bottles).

Degassing:
By means of the pressurisation lever, in rest position, opens the third hole of the valves allowing the gradual exit of gas present in the bottles, to the outside.

It is a similar system to that of fully automatic fillers, where the valves act automatically. The valves used are very similar.

Options:-

Injection of clean CO2, before the filling process, directly from the cylinder, 800 Euros
Additional tubes for different fill level per bottle, 28 Euros each
Upgrade for filling PET bottles, 1060 Euros
Special 'dummy' bottles for sanitising after use, 109 Euros each
Automatic front sliding door protection, 499 Euros
Fully automatic cycle, 1560 Euros
Automatic sliding door for automatic cycle, 800 Euros
Liquid re-circulation for rinser, ...

Some advice:-

1. For filling beer, the pre-evacuation system and also the CO2 injection is recommended. We have had very good success with the Rz fillers in small breweries and all of them are working with these features. CO2 injection gives additional product security.

2. How sensitive to filling is the temperature of the beer from the pressure tank ?
The lower the temperature, the less foam you will have in the filler tank and in the bottle during filling.

3. What does the 'Automatic sliding door protection' option do ? The door is necessary for safety of the operator (the moving piston and also the possibility of breaking bottles). On the standard machine the opening of the door is manual. As an option you can have automatic opening of the door by pneumatic piston.

4. Are the dummy bottles really essential, or can ordinary glass bottles be used ? Of course you can clean also with ordinary glass bottles. Using the dummy bottles you have the possibility to make a re-circulation of the cleaning solution. Working with glass bottles you need to empty the bottles several times while cleaning, at the end of a day.

    Barida: semi-automatic filler:-

  

ISO 4 (4 nozzles):  10,750 Euros
         output is estimated at 266 x 75cl bottles/hour
                   or 400 x 33cl bottles/hour;
  one of my customers averages 350 x 33cl bottles/hour.

Bottles from 330 ml to 1.5 litres.
Level probe for automatic liquid inlet. Low foam filling system by distributing the liquid on the bottle wall.
Pneumatic bottle-lift with bottle centering device.
Stainless steel filling nozzles, with heat-sanitisable seals.
Front safety panel with safety lock. Weight 160 kilos.
Stainless steel non-return valve on the in-feed pipe.
Maximum working pressure is 5 bar; tested to 5 bar.

Set of 4 pipes for changing the bottle fill level, 160 Euros
'dummy' bottles for sanitising after use, 130 Euros each
Upgrade for filling PET bottles, 1600 Euros
Mounted on wheels, 165 Euros extra.

optional pre-evacuation system, to suck the air out from the bottle before filling (which is good for beers and sensitive wines), 2100 Euros extra.

   User manual iso-4  and a video of use video iso-4   and a 3d drawing  3D iso-4

This model has been standardised with 4 nozzles, this allows a good working flow with one operator as you can see from the video.

0.25 kWatt liquid pump, 220 volt and 24 volt for controls.
A CO2 supply is needed.
The pressure inside the filler's small header tank should be set at equal to or very slightly less than the pressure inside the main storage tank (which should be at 2 bar), so the liquid will be transferred very slowly to minimise foaming.

A compressed air supply is required, to be connected to the filler:-

The air compressor needs to be able to supply at least 245 litres/minute (8 cubic feet/minute) at above 4 bar. It should be set 2 bar above the pressure in the supply tank (around 2 bar); so typically the range is 3.5 to 4.5 bar.

The maximum air consumption for all four pneumatic cylinders simultaneously would be 300 litres/min. However, it is a semi-automatic unit and the four bottle-lifting pistons do not operate at the same time, so the actual consumption is very much lower, typically 38 litres/min.

To ensure a smooth operation they suggest having a compressor with at least 3 Hp and 150 litre air-receiver-tank. That gives plenty of capacity to operate a small pneumatic crown capper as well.
The compressor must be rated at max 10 bar, so that it can be set at up to 7 bar without issues.

On the air inlet to the ISO-4 are two transparent chambers:-
the LH chamber is a 'lubricant' chamber and has a 'minimum level' marked on it. It must contain a mineral oil for pneumatic components, something like http://www.rapidonline.com/Mechanical-Fastenings-Fixings/Air-Tool-Oil-1l-89-0290
the RH glass chamber is the condensate collector for water from the air supply, which needs to be drained occasionally.

The height adjustment of the lifting pedestals to fit bottles with different height is automatic.
Bottle heights from 150 to 380 mm, diameters from 50 to 114 mm.

     

In order to change the filling level of the liquid inside the bottle, it is necessary to replace the set of level-pipes in the filling valves.
With shorter pipes, the level of the product in the bottle will be higher.
With longer pipes the level will be lower.

Whether you need different pipes depends on how precisely you wish to fill. In theory each bottle with a difference in fill height of even 2mm should have its own set of pipes, but it may be better to overfill slightly in order to avoid changing the pipes for each different bottle.

The pneumatic bottle-lift is not the only difference between this and the CEM model (listed below):-

- the filling nozzles on the Barida are the same as are used on automatic CP-fillers.
- the CEM is totally manual, you have to control the working phases (counter-pressure - filling - de-gasing) all by a handle (one for each valve). On the Barida filler, the counter-pressure phase is followed automatically by filling.
- the CEM machine can't be completely sterilised, the hoses for return of the air (de-gasing) can't be really thoroughly cleaned. On the Barida you can perform a sterilising cycle, even steaming, as on automatic CP-fillers.
- the CEM machine has working pressure up to 3 bar, the Barida filler has working pressure up to 5 bar.
- the CEM filler has a simple 'floater' to adjust the product level in the bowl, the Barida filler has an electric probe system as on automatic CP-fillers.
- the Barida filler has a 'non-return' valve on the product inlet, to avoid flow back from the filler's bowl: this is important to stabilise the product level in the bowl.




    CEM:  2 or 4 bottle manual fillers:         

bench-mounted, with a simple construction concept, ideal for small producers.
    with 2 nozzles: up to 100 bottles/hour, 4,500 Euros
    with 4 nozzles: up to 200 bottles/hour, 6,140 Euros
    
with 4 nozzles to fill either bottles or 5 litre kegs (40 kegs/hour), with pneumatic lifting of the kegs, 8,570 Euros

Note: 4 nozzles is the maximum that one operator can manage with a counter-pressure manual filler. The manual filler requires quite a lot of manual handling, not only to place and remove the bottles but also to control the different working phases (counter-pressure - filling - degasing).

The outputs above are approximate, the hourly rate is dependent on the amount of CO2, the temperature, and the bottle capacity.
It is possible to fill glass and PET bottles from 330 ml to 1.5 litres; maximum diameter 12 cm, maximum height 33 cm, not conical. Maximum filling level is 6 cm from top.

At the top of the machine is a small header tank with pressure gauge. Maximum working pressure is 3 bar; although the tank is tested to 5 bar.
There are front protection covers and stainless steel panels between each bottle.
Most of the components are in steel and metal alloys, while all the parts in contact with the product are made of stainless steel.

The bottle-pedestals can be adjusted to accommodate different bottle heights by a simple motion on a toothed shaft.

The operator places the bottle on the pedestal and lowers a lever to start the filling process.

No-foaming: the bottle is positioned slightly inclined, the filling valve is designed with product out-feed on the rear-side to reduce foaming during the filling process.

Size: 1250mm wide x 600mm deep x 930mm high.

Delivery time 90 days from order.


Prices shown are exclusive of Vat.
Delivery usually will need to be charged at cost.

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