Winegrowers Supplies  -  Semi-automatic isobaric (counter-pressure) bottle fillers

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

For 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 drink (when inside the filler's header tank) should be between - 1 C and + 2 C.
At higher pressure there will be more foaming in the filler tank and in the bottles when filling.

    RZ: semi-automatic isobaric fillers:  delivery time about 9 weeks from order:-

RZ-4: 4 nozzles, 11,360 Euros
         Output is from 200 to 400 x 75 cl bottles/hour. The output depends on the type of drink, its temperature, pressure and if the pre-evacuation option is chosen.
         1800 mm x 700 mm x 2100 mmH, 250 kilos.

RZ-6: 6 nozzles, 15,995 Euros
         2200 mm x 700 mm x 2100 mmH, 300 kilos.

RZ-2: 2 nozzles, output from 100 to 200 x 75 cl bottles/hour, 7,575 Euros

A compressed air supply is required, to be connected to the filler, the air consumption for 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.
There are two ball-valves at the bottom and top of the tank to facilitate washing out after use.
There is a DIN25 male thread on the inlet.

The filler processes all bottles simultaneously; it is necessary to have a bottle under each nozzle. Bottle height from 140 to 350 mm.

The bottle filling nozzle-valves, in addition to the filling hole and central level tube, 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 ('snifting').
All of these holes are normally closed, until they are opened by manually operating pneumatic levers.

The pre-evacuation is made with a vacuum pump. Filling is much faster after pre-evacuation.
The other advantage of pre-evacuation is that if the air in the bottle is 'stale', that air is removed outside the filler instead of going back into the top of the filler header tank.

At the start of filling there is high pressure in the filler tank (between 1 and 5 bar) and no pressure in the bottle.
Inside the filling-valve there is a spring balanced seal which is pushed downwards by the pressure inside the filler tank so the valve is closed tightly.
Next the gas from the filler tank or from an external gas cylinder will flow into the bottle and is set to reach exactly the same pressure as in the filler tank.
Now the pressure in the filler tank and bottle are equal, so the spring balanced seal will open the filling-valve.
The liquid will flow under gravity into the bottle, without pressure, because you have for example 3 bar in the filler tank and exactly 3 bar in the bottle in this moment. The flow stops when the liquid level reaches the vent pipe, as with a normal gravity filler.

At the time of buying a filler, it is necessary to choose one of 4 'configurations' for different filling cycles. The choice depends on the drink you will be filling:-

Configuration 4: Standard: with just 2 pneumatic levers, operated manually in sequence, to control the functions:-

   lever 1: the bottle is lifted up (step 1) and once the valve is open the CO2 gas compensates for the pressure difference between bottle and filler.
      once the pressure is equal the filling starts (step 2). Once the set filling level is reached the filling is complete and the valve is closed by using lever 1.
   lever 2: this starts the snifting (the gas pressure inside the bottle neck is released and the valve will close), the bottle is then lowered by moving lever 1 into the original position.

Configuration 3: 2160 Euros extra, with pre-evacuation: by means of 3 pneumatic manual levers in sequence, which operate all the functions:-

   lever 1: the bottle is lifted up (step 1) and the valve opens.
   lever 2: pre-evacuation of the bottle, removing most of the air from the bottle.
   lever 3: clean CO2 gas compensates for the pressure difference between bottle and filler,
      once the pressure is equal to that in the filling tank, the filling starts (step 2). Once the set filling level is reached the filling is complete and the valve is closed by using lever 1.
      Automatically this starts the snifting (the gas pressure inside the bottle neck is released and the valve will close), the bottle is then lowered by moving lever 1 into the original position.

Configuration 2: 2800 Euros extra, semi-automatic, with all options: by means of 3 pneumatic manual levers and 1 electric, used in sequence to operate all the functions:-

   lever 1: the bottle is lifted up (step 1) and the valve opens.
      pre-evacuation of the bottle, removing most of the air from the bottle.
      Followed by injection of clean CO2 gas into the bottle. This minimises oxidation of the drink while filling, but uses a lot of CO2 gas.
   lever 2: clean CO2 gas compensates for the pressure difference between bottle and filler,
      once the pressure is equal to that in the filling tank, the filling starts (step 2). Once the set filling level is reached the filling is complete and the valve is closed by using lever 1.
   lever 3: this starts the snifting (the gas pressure inside the bottle neck is released and the valve will close), the bottle is then lowered by moving lever 1 into the original position.

Configuration 1: 2800 Euros extra, complete manual control: by means of 5 pneumatic manual levers, to operate all of the functions individually:-

   lever 1: the bottle is lifted up (step 1) and the valve opens.
   lever 2: pre-evacuation of the bottle, removing most of the air from the bottle.
   lever 3: injection of clean CO2 gas into the bottle. This minimises oxidation of the drink while filling, but uses a lot of CO2 gas.
   lever 4: clean CO2 gas compensates for the pressure difference between bottle and filler,
      once the pressure is equal to that in the filling tank, the filling starts (step 2). Once the set filling level is reached the filling is complete and the valve is closed by using lever 1.
   lever 5: this starts the snifting (the gas pressure inside the bottle neck is released and the valve will close), the bottle is then lowered by moving lever 1 into the original position.

To cut the vent pipes on the filling valves to the correct length, the manufacturer needs to receive sample bottles.
The shape of the bottle neck has a big influence, also the CO2 pressure, temperature and the type of the drink to be filled.
The filling level must allow for the expansion in volume after the drink warms up to the specified fill-level for the bottle.

Options:-

Bottle pre-rinser, 276 Euros per bottle

Special 'dummy' bottles for sanitising after use, 109 Euros each
you can sanitise with the normal glass bottles; however, using the special dummy bottles you can make a re-circulation of the cleaning solution.
Using the normal glass bottles you need to empty the bottles several times while cleaning at the end of a day.

for Cleaning In Place:-
CP non return valve stainless steel, 200 Euros
CP CIP cleaning collector, 154 Euros

Additional level pipes for different bottle fill levels, 22 Euros each, one set is supplied.
Upgrade for filling PET bottles, 179 Euros
Automatic front sliding door protection, 455 Euros
The front door is necessary for safety of the operator; because of the moving piston and also the possibility of breaking bottles.
On the standard machine the opening of the door is done manually. As an option you can have automatic opening of the door by pneumatic piston.

RLC1 crown capper attached, 6990 Euros extra.

Some advice:-

1. For filling beer, the pre-evacuation system and also the CO2 injection is recommended. To remove the air in the bottle before filling will avoid 'oxidation' during filling.
We have had very good success with the RZ fillers in small breweries and all of these 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.

    Barida: semi-automatic filler:-

  

ISO 4 (4 nozzles):  ..... 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), 2200 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 2 mm 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.


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

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