Liquid Filling
The Breitner Company of Schwäbisch Hall, Germany, are market leaders in the manufacture of fillers for liquid products.
In linear or rotary design, no other filling system comes close to matching the BREITNER for cost effective, efficient production coupled with unparalleled flexibility.
Third generation, privately owned, Breitner, have been manufacturing bottle fillers for some 50 years and have during their history amassed an unparalleled level of experience in handling different products into different bottle forms, utilising different filling methods.
Today’s Breitner filling machine range combines a level of flexibility and machine build quality unmatched by any other manufacturer. Engineers are trained to meet the highest German apprentice standards and over 90% of all components are manufactured in–house, ensuring the highest levels of traceability.
The loyalty of customers to Breitner equipment is perhaps the company’s greatest testimonial. Primary reasons for this were stated as “the ease of change over from one bottle size to another, together with the equipment’s overall efficiency and reliability, its ease of operation and user friendliness are second to none.”
Following years of manufacturing volumetric filling systems, utilising piston valve dosing units, Breitner pioneered the utilisation of both magnetic inductive and mass flow meter fillers. This technology offers you very significant advantages in filling accuracy, reliability, maintenance and both product and time savings on changeover.
No other filling machine manufacturer has the depth of experience in liquid filling technology to match that of Breitner.
The Breitner Filling Machine
– Its Advantages due to ……………….
Inductive & Mass Flow Meter Filling System
First, no other method of filling offers greater filling accuracy than the magnetic inductive or mass flow meter system.
Secondly, Breitner use Endress & Hauser flow meters, recognised as the industry leaders, guaranteeing both accuracy and reliability.
Specific filling accuracy data will be given on your products and containers from filling demonstrations carried out on your behalf, once samples have been tested by Breitner.
A key point to note is that the filling accuracy remains constant, independent of the age of the filler. In other words, the filling accuracy does not deteriorate as the filling system ages in the way that a piston/valve filling system inevitably will.
Furthermore, the filling accuracy is independent of fill volume. You will be aware that with piston/valve fillers, filling accuracy deteriorates for smaller volumes. This does not happen with the Breitner flow meter filling system.
CIP
The Clean in place – CIP system could not be easier to operate and no other system offers such an effective clean. The Breitner system is effectively a “pipe”, there are no entrapped areas for product retention prior to rinsing or full CIP. This ensures a high level of cleanliness and an extremely hygienic system.
With the Breitner system there is no need to take apart any aspect of the machine in order to clean. Not only does this save time but also eliminates the danger of damaging parts during the cleaning process.
Hygiene
A consequential key benefit of the use of flow meters is the high level of hygiene inherent within the filling system.
Due to the simplicity and effectiveness of the CIP system, and the lack of internal seal and entrapped areas, the filling unit itself offers exceptional hygiene; crucially important when filling such bacterially sensitive food products as fresh fruit juices, smoothies, yogurts and other liquid foods.
The filling environment may be fully protected with enclosed sterile air over pressure to avoid the ingress of airborne contaminants.
Product Wastage on Changeover
Due to the unique design of the Breitner product feed tank, the machine may be run virtually “dry” by running down to fill on a single filling head fed from the lowest position of the feed tank.
Hence, at the end of the product run, only minimal product is left in the system so minimising wastage from one product run to the next.
Control of Filling Nozzles
The Breitner machines can be set as a bottom up filler, either just above or below the surface of the product. Furthermore with the Breitner machine, the lift rate of the nozzle may be controlled to ensure it rises at the correct speeds in relation to the varying shape of the container to be filled.
Fill Volume Adjustment
As the system is electronically controlled through the machine’s PLC, each filling head operates independently and may be very simply set up with respect to fill volume by means of the machine’s controls. This avoids any mechanical adjustment of piston stroke, and provides for instant data recording of real time operation.
A “menu” system in the machine’s B&R control system allows for the storage of filling data for many hundreds of products allowing the operator to move from one product run to another extremely easily at the press of a button.
Reliability
Breitner use flow meters from Endress & Hauser, renowned for their quality of design and construction and longevity of life. Even if one unit should fail, the filling line may be run extremely simply utilising all other fill heads, meaning that in such an event, you do not suffer down time of the line until a repair is carried out.
Flexibility
All Breitner filling machines format change over times are minimised utilising smart design and years of experience gained from manufacturing for a wide range of sectors.
Maintenance
The conical valve sits on to an O ring. As the O ring is static, it does not suffer from wear and so requires only infrequent replacement (dependent upon product, circa 6 months). A task costing virtually nothing in terms of parts and easily carried out in minutes!
The Breitner machine is ideal for handling abrasive products. It does this without the usual problems of wear and the added costs associated with running abrasive products through piston/valve fillers.
Breitner Build Quality
Perhaps steeped in the historical philosophy and indeed geographical location of the Breitner Company, build quality is taken as read.
Breitner machines are constructed to a particular high standard to withstand the rigours of years of productive life.
References
The level of satisfaction enjoyed by Breitner machine users is exceptional. We have no hesitation in putting you in touch with those users so that you may discuss their experiences with them direct. We are only too pleased to arrange, where possible, visits to reference sites both here and abroad.
Linear filling machines
A significant advantage of the Breitner linear machine is that it is virtually maintenance free. Apart from the conveyor, the only other moving parts are the servo motor driven filling bridge and the single conical valve in the filling nozzle.
Container formats are changed without the need for replacing machine change parts, ensuring lowest possible operational downtime.
Suitable for a wide range of container shapes & sizes, from 10mL to 35 Litres and filling rates up to 9,000 bph & 15,000 bph using the double track system.
Rotary filling machines
For manufactures that require a large number fills done quickly and efficiently. Manufactured in a compact design, filling rates of 18,000 bph can be achieved for containers ranging in size from 20ml to 2 Litres.
Rotary Monoblock filler cappers minimise machinery footprint in applications that require high output rates and also help to contain liquids in a designated areas.
Piston / Volumetric filling machines
Breitner experience and knowledge in piston filling is well recognised and is still utilised for processing extremely viscose fluids where pressure vessel are not suitable.
Systems have also been developed to improve CIP effectiveness and hygiene levels for sensitive products.
And each machine can manufactured to meet specific site requirements.
