• High speed aseptic bag in box filler
    Alya

    High speed aseptic bag in box filler

  • High speed aseptic bag in box filler

    Alya

    High speed aseptic bag in box filler

Patented Handling System

The combined use of our new patented system for bag handling and brushless servo motors enables to reach the highest speed in the market, absolute precision in spout positioning and reduced equipment wear.

Bag insertion and release has never been so simple and reliable, thanks to a special design of the spout holding plates, also essential for the sterilization process.

The plates carry the fitment through the sanitation path, providing the right exposure to disinfectant vapor and enabling low peroxide consumption, to achieve effective sterilization of any fitment shape at uncompromised speed.

Torque control over each single motion reduces cycle time and preserves performance over time. Our patented solution places ALYA as the new market leader for aseptic bag-in-box fillers.

Innovation: Alya's improved Bag in Box aseptic filling for low-acid products.

The world of Bag in Box by Ing. A. Rossi is constantly evolving. We have developed an innovative technology that makes it possible to fill low-acid products with a high degree of safety in an aseptic environment while guaranteeing a significant reduction in the use of disinfectant solutions.

This innovative technology combines the Alya bag-in-box filling system, which has already been proven in numerous industrial installations, with a sterilisation technique known as VHP (Vaporised Hydrogen Peroxide). This technique uses vapour-phase hydrogen peroxide as the sterilising agent for the machine and the packaging material to be filled. Using this vaporised sterilising agent guarantees a high level of safety on all surfaces and significantly reduces the amount of solution required compared to liquid phase sterilisers.

With certifications that guarantee the safety and reliability of the sterilisation process on FDA-approved packaging, the new generation of Alya aseptic fillers represents a real breakthrough in the low-acid food & beverage filling sector.

With this new component, Alya can fill high-value products such as milk and dairy, non-dairy milk, protein products, purees and low-acid vegetable juices at the highest speed on the market, with low consumption and in complete safety.

Food & Beverage

Aseptic Bag-In-Box (BIB) filling of a wide range of food and beverage products: liquid, viscous, with pieces, high and low acid

Filling of presterilized web bags with: volume from 3 to 20 liters, any 1” and 2” fitment type available on the market

Viscous

Liquid

with Pieces

Plus & Advantages

Up to 50% faster
than market alternatives

99.7% of filled bags
within 0.3% of accuracy

Productivity guaranteed!
99% Uptime

Possibility to add upstream and downstream
modules for a fully integrated process

Equipment configuration
tailored to fit customer requirements

Quick changeover.Minimized setup time
for fitment and volume changes

Core Key Points
 

  1. 1 | Multiline Receiving

    The filler is configured to receive product from multiple aseptic lines according to Customer’s needs. Alya may be inserted in an existing line and included or excluded without stopping production.

  2. 2 | Buffering & Pressurization

    The product is received in a cold aseptic buffer tank, pressurized with sterile air. Filling accuracy is guaranteed by an extremely precise control over product level and pressure.

  3. 3 | Web Feeding

    Connection to upstream optional module (WEB feeder). A High speed linear servomotor feeds the bag and the patented system transports the spout throghout the machine.

  4. 4 | Fitment Sterilization

    Special nozzles nebulize the disinfectant, which is then activated by sterile air. Sterilization with culinary steam is also available as a cost effective alternative for high acid products.

  5. 5 | Auxiliary Fluids Handling

    Steam, sterilized air and disinfectant are prepared and dispensed in the proper amount to the different parts of the machine during each working step.

 
 

  • 6 | Product Flow Metering

    An instrument suitable for the characteristics of the product measures the flow during filling with high precision, regardless of product viscosity or particulate dimension.

  • 7 | Asepting Filling

    Cap removal, bag filling and capping are performed inside the sterile chamber. A special nozzle keeps fitment clean for secure closure and elimination of potential spoilage path.

  • 8 | Web Cutting

    After filling the pre-cut tape (WEB) is tensioned by its own weight and automatically separated by a pneumatic actuator. The divided bag gently slides on an inclined idle conveyor.

  • 9 | Downstream Modules

    Connection to downstream optional modules such as: bag drying, inline weight check and final packaging in carton box. Drums storage is also possible with our robotic solutions.

  • 10 | Vapor Extractor

    After disinfection residual vapor concentration is reduced within regulatory requirments using a centrifugal fan. This feature only applies on disinfectant version for low acid products.

 

Customized Line Layout

Web Feeder

Advantages

+ Improves bags feeding and unwinding
+ Downtime reduction for bags replenishment

Key Features

+ Dynamic buffering of bags
+ Photocell for refill warning
+ Alarm in case of web tearing

CIP System

Advantages

+ Integrated CIP of Alya and aseptic tank
+ Totally automatic

Key features

+ Conductivity and temperature control
+ Configurable recipe
+ Detergent preparation and recovery

Dryng Tunnel

Advantages

+ Complete drying of the bag before cartoning

Key features

+ Fully enclosed tunnel
+ Two compressors
+ Warm air blades above and below the bag

Weighing Rejection Coding

Advantages

+ 100% coded bags within specified weight tolerance
+ Self-optimization of filled weight

Key Features

+ Weighing on load cell conveyor
+ Automatic filling setpoint adjustment
+ Out-of-spec bag rejection before coding
+ Inline laser coding

Bag-in-box Packing Monoblock

Advantages

+ Minimized Footprint
+ Reduced changeover time

Key Features

+ Three machines in one: case erector, packer and sealer
+ Fully automatic and integrated
+ Hygienic version available

alya customized web filler line

Web Feeder

 

Advantages

+ Improves bags feeding and unwinding
+ Downtime reduction for bags replenishment

Key Features

+ Dynamic buffering of bags
+ Photocell for refill warning
+ Alarm in case of web tearing

CIP System

 

Advantages

+ Integrated CIP of Alya and aseptic tank
+ Totally automatic

Key Features

+ Conductivity
  and temperature control
+ Configurable recipe
+ Detergent preparation
  and recovery

Drying Tunnel

 

Advantages

+ Complete drying of the bag
  before weighing, coding and cartoning

Key Features

+ Fully enclosed tunnel
+ Two lateral channels compressors
+ Air blades above and below the bag

Weighing Rejection Coding

 

Advantages

+ 100% coded bags within specified weight tolerance
 prima della pesatura, codifica
+ Self-optimization of filled weight

Key Features

+ Weighing on load cell conveyor
+ Automatic filling setpoint adjustment
+ Out-of-spec bag rejection before coding
+ Inline laser coding

Bag-in-Box Packing Monoblock

 

Advantages

+ Minimized Footprint
+ Reduced changeover time

Key Features

+ Three machines in one: case erector, packer and sealer
+ Fully automatic and integrated
+ Rifiuto prima della codifica
+ Hygienic version available

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