GASTI packaging solutions E - IMA Dairy and Food · requirements for aseptic intermittent motion machines by 4 head (DS 42) or 6 head (DS 62) dosing systems. DOGASEPTIC 82 THE HIGH

P A C K A G I N G S O L U T I O N S F O R C U P S

FS Machines

FILL YOUR PRODUCTS INTO • Pre-formed cups

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SOLUTIONS FOR ALL PACKAGING REQUIREMENTS FOR LIQUID TO PASTY PRODUCTS

Since 1900, GASTI has been reknown for the high quality and reliability of its continuous motion machines. Over the years an extensive range of tailor-made solutions has been developed specifically designed for the packaging of liquid, semi-liquid and pasty products.

The company’s reputation in the international marketplace is based on its many years of experience in specialized fields, which demand the highest product quality with flexible solutions. Whenever food products are to be filled into cups of various materials and shapes, filling and sealing machines for pre-formed cups from GASTI provide a cost-effective and efficient solution.

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FOR LIQUID TO PASTY PRODUCTS

The demand for fresh tasting products with an extended shelf life and retailers requirements for low cost logistic concepts can only be jointly satisfied by utilising modern machine technology capable of meeting all hygienic, economic and high efficiency requisites. GASTI’s broad range of equipment offers the appropriate machine for each product. Our customised FS machines for pre-made cups can handle all types of approved materials.

All machines are known for their extremely high filling accuracy, often using dosing devices without seals and also able to process products with particulates. They can fill all kinds of liquid to pasty products with or without particulates.Covering a wide range of filling styles, countless customised and tailor-made design possibilities are available to satisfy specific requests.

Fillers benefit from automatic fully controlled SIP/CIP-systems for maximum hygiene, and are supplied in full compliance with international standards. On demand, equipment can also be delivered in accordance with further regulations such as FDA, 3A and EHEDG etc.

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COMBISEPTIC 41 FOR SMALL OUTPUT COMBISEPTIC 61 FOR BIG CUP DIAMETERS COMBISEPTIC 81 THE MEDIUM PERFORMANCE SOLUTIONSWell proven cup filling and closing machine for pre-formed cups up to max. Ø 97 mm (CS 41 and CS 81) and Ø 130 mm (CS 61) and up to max. 160 mm height.Output infinitely adjustable up to 9,000 cups/h (CS 41) and 16,200 cups/h (CS 81), covering all small and medium performance requirements for continuous motion machines by 4 head (CS 41), 6 head (CS 61) or 8 head (CS 81) dosing systems. Liquid products can be filled at constant speed throughout the machine, with no acceleration and deceleration forces. Due to the continuous motion concept spillages - especially of low viscous products - can be prevented.

GOOD IDEAS REQUIRE GOOD TOOLS. THE CONTINUOUSLY MOVING COMBISEPTIC PROVIDES YOU WITH THE VERY BEST EQUIPMENT FOR REALIZING YOUR INNOVATIVE PRODUCT CONCEPTS. THE MODULAR COMBISEPTIC OFFERS FLEXIBILITY TO PERFECTION AT A REASONABLE OUTPUT.The ergonomically optimized machine design, combined with the patented GASTI cell plate system, enables short change-over times for changes to completely different formats. Convenient operation from one side of the machine plus the GASTI visualization system minimizes personnel requirements.The COMBISEPTIC (which is the format flexible version of the former DOGATHERM) is able to fill liquid to pasty products such as plain or fruited yoghurt, quark, crème fraîche, mousse, custard, dips, processed cheese etc., with and without particulates, in single and multi-layers. The fillers are driven by servo motors.

COMBISEPTIC SERIES (CLE AN / ULTR A-CLE AN)

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COMBISEPTIC 41/61/81 TECHNICAL DATA

MATERIALS

Cups Pre-made stackable cups made of PP or PS

LidsPre-cut diaphragm lids made of embossed or plain aluminium foil (≥ 40 µm), or made of suitable PET or paper composite films with features for mechanical separation

Snap-on lids Pre-made, stackable snap-on lids made of PET or PP

NOMINAL OUTPUTS

COMBISEPTIC 41 9,000 cups/h



STANDARDS

Standard configuration Vertical cup destacker, filling station (CIP), incl. nozzles & level capacity, diaphragm lid applier, heat sealing, cup lifting out

Hygiene Clean

OPTIONS

Hygiene Ultra-clean

Filling Pre-and post-filler

General Cup stack buffer magazine, particle remover, leakage test, inkjet printing, snap-on lid, format flexibility, servo driven, AIRMATIC

Round cup max. Ø [mm]: format flexible design 97 (CS 41 and CS 81), 130 (CS 61)Fill volume main filler [ccm]:25-250 or 50-500 or 150-1100

Fill volume pre-/post-filler [ccm]:10-60 or 10-160 or 25-250

Min. / max. cup height [mm] 50/160

9,500

3,100

1,700

Machine

A: 9,500 B:1,700 C: 3,100A B

C

Necessary Room

A: 10,500 B:3,200 C: 4,100A B

C

*Other formats on request

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CONTITHERM 123 THE MEDIUM OUTPUT SOLUTIONWell proven cup filling and closing machine for pre-formed cups up to max. Ø 95mm and up to max. 130 mm height. Output infinitely adjustable up to 28,800 cups/h, covering all medium performance requirements with continuous motion of the cups, by 12 head dosing systems.No permanent acceleration and deceleration forces as by the “stop and go” movement of an intermittently operated machine.

CONTITHERM 162 THE HIGH PERFORMANCE SOLUTIONThe ideal solution for your high performance requirements with an output up to 40,320 cups/h. State-of–the-art development with continuous transport of cups for low viscous products and 16 head dosing system.

THE NAME OF THE CONTITHERM IS DERIVED FROM ITS CONTINUOUS MOTION WORKING PRINCIPLE I.E.

The cups are conveyed through the machine with constant speed, the filling nozzles and the sealing station oscillate during the filling and sealing operation synchronically with the cup conveyor.

CONTITHERM SERIES (CLE AN / ULTR A-CLE AN)

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CONTITHERM 123 TECHNICAL DATA

MATERIALS


LidsPre-cut diaphragm lids made of embossed or plain aluminium foil , or made of suitable PET or paper composite films with features for mechanical separation


NOMINAL OUTPUT

CONTITHERM 123 28,800 cups/h

STANDARDS

Standard configurationServo-driven, vertical cup destacker, filling station (CIP), incl. nozzles & level capacity, diaphragm lid applier, heat sealing, cup lifting out

Hygiene Clean

OPTIONS

Hygiene Ultra-Clean

Filling Pre-filler, pre and post-filler

General Cup stack buffer magazine, particle remover, leakage test, inkjet printing, snap-on lid, servo driven

Round cup max. 0 95 mm Fill volume main filler 30-300 or 50-500 ccm

Min. / max. cup height 30/130 mm Fill volume pre-/post-filler 12,5-125 or 30-300 ccm

9932 415980

1050

2470

Machine

Version 1: (for max. 2 filler)A: 9,112 B: 1,500 C: 3,000Version 2: (for max. 3 filler)A: 9,932 B: 1,500 C: 3,000

A B

C

Necessary Room

Version 1: (for max. 2 filler)A: 13,000 B: 4,500 C: 3,500Version 2: (for max. 3 filler)A: 14,000 B: 4,500 C: 3,500

A B

C


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CONTITHERM 162 TECHNICAL DATA

MATERIALS




NOMINAL OUTPUT

CONTITHERM 162 40,320 cups/h

STANDARDS

Standard configurationServo driven, vertical cup destacker, filling station (CIP), incl. nozzles & level capacity, diaphragm lid applier, heat sealing, cup lifting out

Hygiene Clean

OPTIONS

Hygiene Ultra-Clean (upon request)

Filling Pre-filler, pre and post-filler

General Cup stack buffer magazine, particle remover, leakage test, inkjet printing, snap-on lid

Machine

Version 1: (for max. 2 filler)A: 9,400 B: 2,300 C: 3,000

A B

C

Necessary Room

A: 13,000 B: 5,300 C: 4,000A B

C

3000

9400

Round cup max. 0 95 mm Fill volume main filler 30-300 or 50-500 ccm

Min. / max. cup height 30/130 mm Fill volume pre-/post-filler 12,5-125 or 30-300 ccm


THE GASTI DOGASEPTIC WAS DESIGNED FOR MULTI-LAYER AND ASSORTED FILLING OF LIQUID TO PASTY PRODUCTS, WITH OR WITHOUT PARTICULATES. ALL TYPES OF YOGHURT AND DESSERTS SUCH AS CUSTARD, PUDDING AND MOUSSE, WITH AND WITHOUT CREAM TOPPINGS, ARE FILLED UNDER ASEPTIC CONDITIONS.

HIGH PRODUCT VARIABILITYLiquid to pasty products can be filled in single and multiple layers, with or without particulates, e.g. yoghurt (plain or fruited), chilled desserts, crème fraîche, processed and fresh cheese, sauces, jams, honey and soups. With a special machine execution, it is also possible to fill dehydrated soups, muesli, confectionary, etc.

DOGASEPTIC 42 FOR LOW OUTPUT DOGASEPTIC 62 THE MEDIUM PERFORMANCE SOLUTIONWell proven cup filling and closing machine for pre-formed cups up to max. Ø 115 mm (DS 42) and Ø 75 mm (DS 62) and up to max. 130 mm height.Output infinitely adjustable up to 9,600 cups/h (DS 42) and up to 14,400 cups/h (DS 62), covering all small and medium performance requirements for aseptic intermittent motion machines by 4 head (DS 42) or 6 head (DS 62) dosing systems.

DOGASEPTIC 82 THE HIGH PERFORMANCE SOLUTIONThe ideal solution for your high performance requirements. State-of–the-art development with dosing units without moving seals, which is sterilizable by steam.Well proven cup filling and closing machine for pre-formed cups up to max. Ø 95 mm and up to max. 130 mm height. Output infinitely adjustable up to 20,160 c/h , covering all high performance requirements for aseptic intermittent motion machines by 8 head dosing systems

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DOGASEPTIC (ASEPTIC)

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DOGASEPTIC 42/62 TECHNICAL DATA

MATERIALS




NOMINAL OUTPUTS

DOGASEPTIC 42 9,600 cups/h


STANDARDS

Standard configuration Vertical cup destacker, filling station (CIP), incl. nozzles & level capacity, diaphragm lid applier, heat sealing, cup lifting out

Hygiene Aseptic

OPTIONS

Hygiene Downgrade to Ultra-clean

Filling Pre and post-filler

Generalcup stack buffer magazine, particle remover, leakage test, inkjet printing, snap-on lid, format flexibility, STERIMATIC, servo driven

Round cup max. Ø 115 mm (DS42)75 mm (DS62)

Fill volume main filler [ccm] 25-250 or 50-500 or 70-700

Max. cup height130 (DS42)115 (DS62)

Fill volume pre-/post-filler [ccm] 12,5-125 or 25-250

2445

5006

Machine

C

A: 5,006 B:1,850 C: 2,650A B

Necessary Room

A: 8,000 B:4,000 C: 3,200A B

C


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Machine

DOGASEPTIC 82 TECHNICAL DATA

MATERIALS




NOMINAL OUTPUT


STANDARDS

Standard configurationServo driven, vertical cup destacker, filling station (CIP), incl. nozzles & level capacity, diaphgram lid applier, heat sealing, cup lifting out

Hygiene Aseptic

OPTIONS

Hygiene Downgrade to Ultra-clean

Filling Pre and Post-Filler

General Cup stack buffer magazine, particle remover, leakage test, inkjet printing, snap-on lid, format flexibility, STERIMATIC

Round cup max. Ø [mm] 95 mm Fill volume main filler [ccm] 25-250 or 50-500

Min. / max. cup height [mm] 50/130 Fill volume pre-/post-filler [ccm] 12,5-125 or 25-250

3200

87501250

A: 8,750 B:2,200 C: 3,200A B

C

Necessary Room

A: 10,500 B:3,200 C: 4,100A B

C

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ALL KIND OF FILLING SOLUTIONS

With its’ long term experience in filling liquid to pasty products into different kind of pre-formed cups GASTI offers a large variety of different filling possibilities. The fillers are known for their outstanding filling accuracy, a factor which inevitably leads to minimal product loss and enhanced productivity.Covering a wide range of filling styles, countless customized and tailor-made design possibilities are available to satisfy specific requests.Built to ensure maximum flexibility, different products can be processed on the same machine, which can also handle small and large volumes. Fillers benefit from automatic, fully controlled SIP/CIP systems for maximum hygiene, and are supplied in full compliance with international standards.On demand, equipment can also be delivered in accordance with further regulations such as FDA, 3A and EHEDG etc.

Fresh products CLEAN

Long life products ASEPTIC

Extended shelf life products ULTRA-CLEAN

The requirement to extend the shelf life of high-quality products outside as well as throughout the cooling chain – without a loss of quality – is becoming increasingly important.

The packaging process can be split into various hygiene classes, depending on application or product requirements. GASTI solutions comply with the following hygiene standards:

◾◾ clean

◾◾ ultra-clean

◾◾ aseptic

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HYGIENE LEVELS HYGIENE LEVELS

TEAMIMA DAIRY & FOOD has an Aseptic Competence Center in Ranstadt with a a team of specialists for hygienic and aseptic filling systems with expertise in the fields of process engineering and microbiology.The team consists of food technologists, process engineers, mechatronics and laboratory technicians with experience in the areas of food processing and packaging, process engineering, microbiology, regulatory.We provide the complete solution from a single source: from planning through engineering to the final acceptance of a filling line.For validation, trouble shooting, inspection or optimization of your existing plant our team is the perfect contact.For microbiological validation we provide you with advice, support you during execution and offer sample preparation and post-processing in our own laboratory.

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ASEPTIC COMPETENCE CENTER

OUR SERVICE

We are able to assemble special decontamination units at our workshop according to customer requirements and conduct microbiological tests with them.

ON SITE SUPPORT

◾◾ Microbiological risk assessment

◾◾ Verification of the efficiency of the decontamination process (Challenge Test)

◾◾ Revalidation after modification

◾◾ Initial germ count of packaging

◾◾ Verification of machine reaction to Critical Control Points (CCP)

◾◾ Determination of residual oxygen / peroxide in packaging

◾◾ Environmental monitoring

◾◾ Challenging the maintenance of sterility with small particle smoke

◾◾ CIP Validation

CIP OPTIMISATION

◾◾ Registration of CIP recipe and verification of all cleaning steps

◾◾ Control of the given recipe procedure

◾◾ Sample from rinse water after each step and at the end of CIP

◾◾ Determine TOC (total organic carbon) and TIC (total inorganic carbon) values in the laboratory of our proven partner

◾◾ Identify savings potential or improvement potential

◾◾ CIP revalidation

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ASEPTIC COMPETENCE CENTER

LABORATORYOur microbiological laboratory is certified for biosafety level II in Germany. We are qualified to handle microorganisms up to risk level II, e.g. Aspergillus brasiliensis, a widely used indicator organism. The facility is highly equipped for microbial count, media preparation, sample processing, incubation and evaluation.

In our physical laboratory we offer:

• pH measurement

• Conductivity measurement

• Viscosity measurement (acc. Bostwick)

• Brix measurement

• Air sampling (particle)

• Temperature profile (IR camera)

Example of a CIP (cleaning in place) - Time Duration Not Considered: Concentration (%), Temperature (°C), Pressure (bar)

CIP Pre-rinse 5 minutesCIP Pre-rinse 2 minutesCIP Final Rinse 10 minutesCIP Nitric Acid 20 minutesCIP Intermediate Rinse 5 minutesCIP Caustic 20 minutes

IMA DAIRY & FOOD PARTNERS THE INDUSTRY AT EVERY LEVEL, PROVIDING CLOSE SUPPORT DURING THE DESIGN PHASE PRIOR TO DEFINING THE SOLUTION AND ALSO ENSURING FULL TECHNICAL ASSISTANCE AT THE CUSTOMER’S SITE THROUGHOUT THE ENTIRE LIFE-CYCLE OF A MACHINE.

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A team of experts is available to respond to any mechanical or electrical issue and skilled engineers are on call at IMA branches worldwide.In order to assure the highest level of technical assistance, all IMA technicians are fully trained and kept constantly up to date with the latest technical developments in their sector. Having locally based technicians brings IMA closer to the customer. This gives greater insight into real production requirements and specific market needs, and leads to more appropriate solutions that can also be achieved by customization wherever necessary.Our remote service assistance enables instant and secure connection between the customer’s equipment and our support team who can quickly view, diagnose and troubleshoot. Investment in GASTI machinery is a sound choice as existing machines are open to upgrading with new technologies.

TECHNOLOGICAL IMPROVEMENTS

◾◾ Conversions

◾◾ Upgrades

◾◾ Refurbishments

◾◾ Pre-owned equipment

◾◾ Obsolete technology replacement

◾◾ Service contracts

ONE PARTNER FOR ALL YOUR NEEDS

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OPERATIONS SUPPORT

◾◾ Field service

◾◾ Spare parts

◾◾ Inspection agreements

◾◾ Remote services

◾◾ Relocation

PRODUCTIVITY ASSISTANCE

◾◾ Auditing

◾◾ Training

◾◾ Operative support

◾◾ Consulting

Erca S.A.S.3, Avenue du PacifiqueLes Ulis, B.P. 5491942 Courtaboeuf Cedex / FranceTel. +33 169 828 000Fax +33 169 078 238

Erca-Formseal Ibérica S.A.Paseo del Ferrocarril, 339Planta 1a - Puertas 1 y 208860 Castelldefels (Barcelona) - SpainTel. +34 93 662 38 00Fax +34 93 662 54 58

Hassia Verpackungsmaschinen GmbHHeegweg 1963691 Ranstadt - GermanyTel. +49 6041 81 0Fax +49 6041 81 344

IMA Dairy & Food USA, Inc. 7, New Lancaster RoadLeominster - MA 01453 / USATel. +978 227 1210Fax. +978 840 0730

GASTI Verpackungsmaschinen GmbHRaiffeisenstrasse 874523 Schwaebisch Hall - GermanyTel. +49 791 402 0 Fax +49 791 402 100

Visit our website www.imadairyfood.com for contacting our worldwide agent network.

IMA Dairy & Food UK Ltd. Retford Enterprise Centre - Randall WayRetford DN22 7GR - United KingdomPhone +49 173 666 1120

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DIRECT CONTACT TO IMA DAIRY & FOOD LOCATIONS

Visit our website www.imadairyfood.com for contacting our worldwide agent network.

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www.imadairyfood.com

GASTI Verpackungsmaschinen GmbHRaiffeisenstrasse 874523 Schwaebisch Hall - GermanyTel. +49 791 402 0 Fax +49 791 402 [email protected]

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Documents

GASTI packaging solutions E - IMA Dairy and Food · requirements for aseptic intermittent motion machines by 4 head (DS 42) or 6 head (DS 62) dosing systems. DOGASEPTIC 82 THE HIGH