With the development of the 100,000 BPH ErgoBloc L, Krones has set a new benchmark in block technology. Designed to meet the rising demand for packaged water, this innovative system offers superior performance in terms of energy and media consumption per packaged unit compared to multiple medium-output lines. The ErgoBloc L achieves an impressive output of 100,000 0.5-litre water bottles per hour, establishing a new standard in the industry.
Advanced Production Sequence
The 100,000 BPH block operates similarly to a conventional ErgoBloc L but with notable advancements. The biggest challenge was the filler, as the “bigger carousel equals higher output” approach reached physical limits. To address this, the system features two modularised filling and closing units, distributing the workload while maintaining stability. Despite having two units, the system operates as a single integrated block with one valve rack and one sorting system for closures. The Modulfill Dual, with about 60 fewer filling valves than a single-filler solution, takes up less space while delivering nearly 20 per cent higher output.
Innovative Components and Features
Krones has integrated cutting-edge technologies into the high-speed block. Components from the fourth Contiform generation, such as skip-and-run technology, are used in this block. This technology monitors the mold-hanger locking device, allowing a blowing station that is not locked to pass along the main cam, enabling the ejection of defective preforms without stopping the machine. This reduces scrap rates and minimizes the need for operator intervention.
Krones also developed Contiloop AI, an automatic process control system. Combining AI-based software and new hardware, Contiloop AI detects slight variations in material distribution during PET container production and adjusts key stretch-blow-molding parameters in real-time. This ensures consistent bottle quality, particularly with rPET.
Eco-Friendly and Cost-Effective Operation
In designing the stretch blow-molder, Krones focused on eco-friendly, sustainable, and cost-effective operation. By shortening the distance between heaters and redesigning them with parabolic reflectors, they reduced the heating space's size and cut energy consumption by 11 per cent compared to the previous generation. The new Air Wizard Triple air recycling system, utilising a three-stage compressed-air recycling process, further reduces compressed air consumption by up to 20 per cent.
Enhanced Labelling and Sustainability
To handle the high output of the stretch blow-molder, the ErgoBloc L incorporates optimised components and functionalities. The Ergomodul features two Contiroll labeling stations and Multireel magazines for label reels, with a new buffer system maintaining constant label tension. This is ideal for thin label films, promoting sustainability. The machine also includes a "no bottle – no label" function, which prevents label and glue waste by retracting vacuum cylinder suction bars when there is a gap in the bottle flow entering the labeller. This ensures that gaps in the container flow do not affect the line's efficiency.
Conclusion
The ErgoBloc 100,000 BPH represents a significant advancement in bottling technology, combining high output with energy efficiency, reduced waste, and improved sustainability. Krones' innovative approach to filling, labelling, and blow-molding ensures that the system meets the demanding requirements of modern beverage production, setting a new standard for the industry.
