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桶装扎啤酒自动清洗灌装线设计方案

KEG WASHING AND FILLING LINE WITH AUTOMATIC PASTEURIZER

DESIGN AND QUOTATION

 

一. 设备配套方案及能力设计:

全套设备由二条连体结构的清洗、灌装线主机;一个主电气控制箱;一套自动称重及推出装置;一套用于扎啤桶自动输送的走链输送系统及相关配套的蒸汽、CO2过滤器等组成。

设备按客户需要以容积30L标准不锈钢保温桶为参照标准设计,按一条自动清洗、灌装线60/小时能力设计。

A. Equipment matching scheme and design ability:

A full set of equipment is including two conjoined structure including of cleaning, filling line host, a main electric control box, a set of automatic weighing system,  a set of automatic conveyor system and related steam and CO2 filter and so on。

According to the customers' ans standard keg is 30L stainless steel keg as reference, an automatic cleaning, filling line capacity is 60 PCS/hour .

设备列表 ( Equipment list ):

序号

No。

名 称

Name

规格型号

Specification

单位

Unit

数量

QTY

备注

Remark

1

清洗灌装机

Keg Washing And Filling Line

60pcs/H  

Set

1

直线式

Straight-line

2

瞬时杀菌机

Pasteurizer

2000L/H

Set

1

 

3

缓冲罐

Butter tank

3000L

Set

 

配置:防负压阀一套、防正压安全系统3套、CIP一套

Configuration: a set of negative pressure valve, 3 sets of prevention positive pressure safety system,a set of CIP

4

自动称重系统

Automatic weighing system

120pcs/H最大量程(MAX): 150KGS

Set

1

主要配件瑞士梅特勒-托利多

Main component: Mettler Toledo, Switzerland

5

自动输送带

Automatic conveyor system

120pcs/H

meter

6

不锈钢辊筒式

 Stainless steel rollers

6

减速机

Reducer

秒速时时彩平台  

PCS

3

秒速时时彩平台  

7

过滤器

Filters

CO2

Set

2

 

8

过滤器

Filters

蒸汽

Steam

Set

1

 

9

自力式蒸汽减阀

Self-acting steam reducing valve

DN25

Set

2

 

10

现场安装管道及阀门

Install pipes and valves in scene

DN32/DN40/DN80

Set

1

 

 

二. 设备基本结构及工作流程:(参考设备现场布局图)

1. 设备结构:

清洗灌装线采用U型摆放结构,进桶和出桶的方向保持平行。一套输送走链、一套桶预洗、一台桶外洗、一套预洗不合格推出装置、一套自动称重及不合格推出装置、一套供桶内壁清洗用的CIP系统。设备总体呈U型摆放,进桶走链与平行摆放的清洗、灌装线和出桶走链呈垂直结构,分别位于灌装线的进桶和出桶位置。供桶内壁清洗用的CIP系统位于灌装线结构的中间部分,以便于节省空间。清洗、灌装线通过管路接口与供桶内壁清洗用的CIP系统和外部压缩空气、CO2、蒸汽、酒液等管路连接(现场连接)。

2.工作流程:

待清洗及灌装的空桶通过人工方式摆放到进桶的输送走链上(酒矛口向下),通过输送走链输送到清洗、灌装线的入口位置;在程序控制下,清洗、灌装线通过进桶、移桶装置使桶移动到工位1的位置开始进行刷洗;工位1刷洗流程完毕后,移桶装置动作,将桶从工位1移动到工位2,开始进行工位2的刷洗流程;同时移桶装置动作时将下一个桶移动到工位1进行工位1的刷洗流程。通过每一次的移桶动作,使每个桶都按流程在工位1到工位6完成刷洗、杀菌、灌装的过程。灌装后的成品通过各线的移桶装置推到出桶输送走链上,再通过输送走链输送到称重装置上进行称重;重量合格的产品通过输送走链输送到成品区域,重量不合格的产品在经过称重推出装置时推到重量不合格区域。

B. Structure and work procedure: (reference design drawing in scene)

1. Structure:

Clean the filling line by using the u-shaped structure, the keg inlet and outlet is kept parallel。 A set of conveyor chain, a set of pre-wash, a set of outside washing, a set of prewashing unqualified roll-out devices, a set of automatic weighing and disqualified roll-out devices, a set of CIP system for the cleaning of the keg’s inner wall。 The equipment is generally u-shaped, and the inlet conveyors and outlet conveyors  are vertical with keg filling and washing line respectively。 The CIP system for cleaning the inner wall of the keg is located in the middle part of the filling part so as to save space。 The washing and filling line is connected with the CIP system, external compressed air, CO2, steam, beer pipe and other pipe connections (site installations ) through the pipe interface and the cleaning of the inner wall of the keg。

2. Work procedure:

(1) Put keg up-down on the conveyor, keg will prepare working automatically.

(2) Keg will prepare working automatically move to station 1 begin washing.

(3) Keg will move to station 2 washing automatically, at the same time, next keg will move on station 1 to prepare washing.

(4) Keg will finished wash, sterilize and fill from station 1 to station 6 as the same way.

(5) Keg will move on the weighing system to check up to standard or not by the conveyor.

 

 

三、 各部分性能介绍:

1. 清洗、灌装线主机:

(1)本机是啤酒桶装容器专用清洗灌装设备。本机配套一套清洗、灌装头装置,可以通过互换方式适用井式酒矛和板式酒矛的不锈钢扎啤桶的清洗及灌装。

(2)本机采用全自动工作方式,自动完成桶的各工位转移及各工位的清洗及灌装,无需人员手动操作。

(3)配套有单独清洗功能,只清洗不灌装,可作预洗机使用。

(4)配套手动操作功能和报警显示功能,便于设备的检修和维护。

(5)实时显示当前的工作状态和工作步骤。

(6)适用于不同容量和标准范围内桶型的扎啤桶。可适应桶高300-500mm;桶直径300-450mm;桶酒矛上端距桶延上端距离小于22 mm

(7)机械传动机构采用机械曲杆联动方式,使设备运行平稳、可靠、定位准确,避免故障率的发生。

(8)设备配有自动压力检测,吹扫后残液检测,酒矛开启检测,杀菌温度检测功能,并带有工位报警,相关工位报警后,下面工位均停止工作并停止灌装,可保证灌装酒理化指标的合格,避免酒的浪费。

(9)灌装采用CO2备压,保压的低压差全封闭灌装方式,灌装量采用进口流量计检测,可根据不同容量桶设定不同的灌装容量。并带有桶的灌满溢流检测,可保证灌装后酒的低沫、低耗,灌装量准确,酒损可控制在1%以下。

(10)设备带有自有CIP及酒管路CIP的刷洗功能,可保证酒管路及灌装头的卫生,使桶装酒符合卫生标准。灌装后的酒保持啤酒的原有口感、口味。

(11)设备灌装采用体积灌装方式,可通过触摸屏设定和调整灌装容量,并可进行误差调节,可实时显示灌装桶数及升数。正常灌装误差可控制在0.2L

(12)设备随机配套CO2过滤器、蒸汽过滤器及减压阀等,保证成品酒的保质期。

(13)单条清洗、灌装线设计能力为60/H30L标准),总能力为。

C. Performance introduction of each part:

1. Main part of Washing and filling line:

(1) This machine is a special cleaning and filling equipment for beer kegs. The machine is equipped with a set of cleaning and filling head, which can be change easily of A,S,D,G, M typer spear.

(2) The machine adopts fully automatic working mode, automatic completion of each station transfer and the cleaning and filling of each station, and no manual operation is required.

(3) There is a separate cleaning function, only cleaning and not filling, which can be used by pre-wash machine.

(4) Supporting manual operation and alarm display function for easy maintenance and maintenance of equipment.

(5) Real-time display of current work status and work procedures。

(6) The bucket of barrels is applicable to different capacity and standard range. It can adapt to the keg height 300-500mm; keg diameter 300-450mm; The upper end distance of the barrel extension is less than 22 mm.

(7) Mechanical driving mechanism adopts the linkage mode of mechanical crank, so that the equipment can run smoothly, reliably and accurately, so as to avoid the occurrence of failure rate.

(8) Device is equipped with automatic pressure detection, residual liquid detection after purging, wine spear open detection, sterilization temperature detection, alarm and location, the location after the alarm, the following location are to stop work and stop filling, can guarantee the physical and chemical indicators qualified filling wine, avoid the waste of alcohol.

(9) The filling is filled with CO2 backup pressure, and the pressure differential is sealed and filled. The filling volume is tested by imported flow meter, and different filling capacity can be set according to different capacity barrels. It can be used to ensure the low foam, low consumption, accurate filling quantity, and the alcohol loss can be controlled below 1%.

(10) The equipment has its own CIP and wine pipeline CIP cleaning function, which can guarantee the hygiene of the wine pipeline and the filling head, so that the wine can meet the hygienic standard。 The wine after filling keeps the original taste and taste of beer。

(11) The filling method of the equipment can be set and adjusted by the touch screen to adjust the filling capacity, and can adjust the error, which can display the number of filling barrels and liters in real time。 Normal filling error can be controlled at 0。2 L。

(12) The equipment is randomly matched with CO2 filter, steam filter and pressure-reducing valve to guarantee the expiration date of the finished wine.

(13) The design capacity of single cleaning and filling line is 60 PCS/H (30L), and the total capacity is.

 

 

设备参数 Equipment parameters

名称

Name

技术参数

Technical Parameter

名称

Name

技术参数

Technical Parameter

生产能力

Capacity

Single line 60PCS/H

碱水浓度

Caustic concentration

1.5%-2%

总功率

Total Power

3phases 6KW

水泵扬程

Pump head

38m

气缸工作压力

Cylinder Working Pressure

0.45~0.5Mpa

碱水温度

Caustic Temperature

80~85

气冲压力

Air Blowing Pressure

0.25~0.3Mpa

热水温度

Hot Water Temperature

85~90

CO2吹扫备压压力

CO2  Pressure Prepare

0.2~0。25Mpa

空气消耗量

Air Consumption

3m3/H

蒸汽压力

Steam Pressure

0.5~0.7Mpa

CO2消耗量

CO2 Consumption

2m3/H

水泵工作电压

Pump Working Power

AC380V/50Hz 3phases

自来水消耗量

City Water Consumption

1500L/H

控制系统电压

Control System Power

DC24 V

蒸汽消耗量

Steam Consumption

2.5m3/H

保压指数

Holding Index

0.1~0.15 Mpa

灌装容量

Filliing Volume

10~50 L

酒管线压力

Beer Pipe Pressure

0.18~0。22Mpa

酒损

Loss Ratio

1%

2.桶内壁清洗用的CIP系统:

(1)系统配套三个CIP水箱和三台CIP水泵;分别为碱水、热水、混合水。三台水泵的最大扬程均为40-45米,配套自动恒压阀供给清洗、灌装线使用。

(2)碱水箱和热水箱具有自动补水,自动加热并恒温功能,保证CIP液的工艺要求。

2。 CIP system for cleaning of keg inner surface

(1)The system has three CIP tanks and three CIP pumps,water tanks is Caustic, hot water and rinse water. The maximum lift of each pump is 40-45 meters. The automatic constant pressure valve is provided to washing and filling line.

(2) Caustic tank and hot water tank have automatic filling water, automatic heating and keeping temperature function to ensure the process requirements of CIP liquid。

 

设备尺寸 Equipment Size

 

主机外型尺寸

Size of main part

L3990×W1060×H2300(M)

设备重量

Weight

1500KGS

CIP水箱容积

CIP tank volume

700L*3

 

60桶/小时标准配置表 Standard configuration sheet

序号

名  称

型  号

数 量

厂 家

1

PLC CPU

S7-300 314

1个

西门子

Siemens

2

模块

PLC modules

321、322

4个

西门子

Siemens

3

触摸屏

Touch panel

KTP1200

1个

西门子

Siemens

4

电器

Electric appliance

断路器、接触器

Breaker、contactor

1套

施耐德

Schneider

5

温控表

Temperature controller

SR3

3个

日本岛电

shimaden

6

铂电阻

Temperature sensor

PT100- 0.2级

3个

福光百特

7

压力开关

Pressure measurement

PS30

5个

台湾亚德客

Airtac

8

音叉液位开关

FTL20H-OTCJ2B

3个

德国E+H

Endress+Hauser

9

水泵

PUMP

CDLF2-4

2台

南方泵业

CNP

10

水泵

PUMP

CDLF4-4

1台

南方泵业

CNP

12

流量计

Flow meter

DN25

1个

德国宝德

Burkert

13

气动阀

Pneumatic valve

DN15-DN32

30个

ESG

14

气缸

Air cylinder

SC80

8个

台湾亚德客

Airtac

15

框架,板料

Frame,

SUS304

 

国产优质

16

管路,管件

Pipes and Lines

SUS304

 

远安

Yuanan

 

 

3.杀菌机(2000L/小时)

设备结构:

啤酒管路系统

由视镜、啤酒入口阀、啤酒高压泵、板式换热器、保温管段、流量调节阀、涡轮式流量计、出口气动蝶阀、循环气动换向阀等组成。

蒸汽管路系统

由蒸汽球阀、蒸汽减压阀、蒸汽气动调节阀、蒸汽换热器等组成。

热水管路系统

由加水阀、立式贮水罐、热水泵、板式换热器等组成。

冷剂管路系统

由过滤器、冷剂阀、冷剂泵、板式换热器等组成。

仪表电控系统

显示仪表有冷剂压力表、啤酒电接点压力表等。控制装置由啤酒流量、杀菌温度、冷却温度PLC及电器元件和指示灯等组成。

工作原理:

准备杀菌的冷啤酒经过高压啤酒泵进入板式换热器,被已完成杀菌的热啤酒预加热到65℃,再被85℃的热水加热到75℃,在保温管段保温30秒后达到巴氏杀菌单位25Pu值,然后再被预热的冷啤酒降温至12℃,最后进入冷却系统被冷却至2℃,进入缓冲罐准备灌装。

操作时杀菌温度低于工艺要求(设定为75)时,可自动进入循环状态,当杀菌温度升到75℃时延时1分钟自动关闭循环阀,开启出酒气动蝶阀,保证杀菌质量。其它控制参数超出设定值时,设备报警并自动停车。

 

 

 

3。PASTEURIZER (2000L/H)

Pasteurizer structure:

Beer piping system

By sight glasses, beer high-pressure pump inlet valve, beer, plate heat exchanger, heat preservation pipe section, flow control valve, turbine flowmeter, exports pneumatic butterfly valve, pneumatic directional valve cycle, etc.

The steam piping system

Ball valve by steam, steam pressure reducing valve, pneumatic control valve, steam heat exchanger, etc.

Hot water piping system

By adding water valve, vertical storage tank, heat pump, heat exchanger, etc.

Refrigerant piping system

By the filters, cooling valve, cooling pump, heat exchanger, etc.

Electric control system of instrument

Display instrument refrigerant pressure gauge, beer electric contact pressure gauge, etc。 Flow control device by beer, the sterilization temperature, cooling temperature, PLC and electrical components and lamp, etc。

Working principle:

Prepare sterilization cold beers after high pressure pump into the plate heat exchanger, have been completed per heated to 65 ℃ heat sterilization of beer, then by 85 ℃ hot water heated to 75 ℃, the heat preservation thermal insulation pipe section after 30 seconds to 25 pu pasteurization unit value, and then be cooled to 12 ℃ preheat the cold beer, and finally into the cooling system is cooled to 2 ℃, into the buffer tank for filling.

Operation sterilization temperature is lower than the technical requirements (set at 75 ℃), can be automatically entered into circulation state, when sterilization temperature up to 75 ℃ delay 1 minute closed automatically circulating valve, pneumatic butterfly valve to open out the wine, ensure the quality of sterilization. Than other control parameters setting, alarm and automatically stop equipment.

 

 

 

2000L/H 标准配置表 Standard configuration sheet

序号

名  称

型  号

数 量

厂 家

1

PLC CPU

S7-200

1个

西门子

Siemens

2

PLC module

EM221\223

2个

西门子

Siemens

3

触摸屏

touch panel

SMART700IE

1个

西门子

Siemens

4

电器

electric appliance

断路器、接触器

Breaker、contactor

1套

施耐德

Schneider

5

流量计

flowmeter

DIN11850R2 DN25

1个

宝德

Burkert

6

铂电阻

PT100- 0.2级

2个

福光百特

7

电接点压力表

1.6MPa

1个

沈阳仪表厂

8

水泵

pump

CDLF2-6

1台

南方泵业

CNP

9

水泵

pump

CHL2-30

1台

南方泵业

CNP

10

水泵

pump

CHL4-30

1台

南方泵业

CNP

11

气动角座调节阀

Pneumatic Angle seat regulating valve

514 25D+1436

1个

德国盖米

GEMuGebr。 Muller

 

气动角座调节阀

Pneumatic Angle seat regulating valve

514 15D+1436

1个

德国盖米

GEMuGebr。 Muller

12

气动薄膜调节阀

Pneumatic diaphragm regulating valve

687 20D+1436

1个

德国盖米

GEMu Gebr. Muller

13

气动蝶阀

Pneumatic Butterfly Valve

DN32

2个

远安

Yuanan

14

气动换向阀

Air Operated Reversing Valve

DN32

1个

远安

Yuanan

15

框架,板料

304不锈钢

秒速时时彩平台  

国产优质

16

管路,管件

304不锈钢

 

远安

Yuanan

17

板式换热器

V-series plate heat exchanger

V13-316L

1套

中法合资维克斯

VIEX

18

板式换热器

V-series plate heat exchanger

V4-316L

1套

中法合资维克斯

VIEX

 

 

4.缓冲罐(3000L无脖法兰锥体罐)

  罐体材质SUS304。

通体壁厚不小于4mm .

内表面镜面抛光,光洁度0.1μm。

罐顶要求配置防负压装置、防正压0。3MPa安全装置、罐内CIP阀、罐内旋转清洗球、CO2备压阀、压缩空气吹扫阀、排气阀、液位CIP阀及电接点压力表。

罐底要求配置DN50卫生级蝶阀。排放1、进酒1、进酒2CIPCIP回、排放、出酒及CIP回泵

控制系统配置手动/自动、CIPCO2、压缩空气、液位清洗、CIP回泵。

4。 Buffer tank (3000 L without neck flange cone)

Container materials SUS304。

The body wall thickness is not less than 4mm.

The inner surface mirror polishing, arrive at 0.1 μm .

Roof requirements to prevent negative pressure device, the positive pressure 0.3 MPa safety device, tank CIP for rotary cleaning ball valve, tank, CO2 pressure valve, compressed air purge valve, exhaust valve, liquid level CIP valve and electric contact pressure gauge.

The bottom of the tank is required to configure the DN50 sanitary butterfly valve。 1。 Enter wine, CIP, CIP, CIP, CIP, wine and CIP back pump

The control system is equipped with manual/automatic, CIP, CO2, compressed air, liquid level cleaning, CIP return pump。

5。称重系统

(1)称重系统是在一台平板式电子秤的上方配套走链输送系统,通过走链的输送使要称重的桶运行到电子称的上方,通过走链暂停后的时间内完成自动的称重过程。

(2)称重后的桶是否达到重量标准是利用桶的实际称重值和称重仪表的设定值来比较判定;实际称重值大于或等于设定值时视为合格。

(3)称重的最大量程为150KG

(4)称重后的桶是否合格由控制系统判定并记忆,当不合格的桶输送到推出装置上时,推出装置自动动作将桶推到不合格区域;合格的桶推出装置不动作,通过输送走链直接输送到成品区域。

5. Weighing system

(1) Weighing system is in a plate type electronic scale above supporting chain conveyor system, go through the chain transmission to run to the electronic weighing barrel according to the above, go through the chain suspension after complete automatic weighing process。

(2) Whether the bucket meets the weight standard is to use the actual weighing value of the bucket and the set value of the weighing instrument to compare the judgment; The actual weighing value is considered qualified if the value is greater than or equal to the set value.

(3) The maximum weight range is 150KGS.

(4) Whether the bucket qualified after weighing is determined by the control system and memory, when the unqualified bucket is delivered to the launch device, the device automatically pushes the bucket to the unqualified area; The qualified drums are not moved, and are transported directly to the finished area through the conveyor chain.

配置表Standard configuration sheet:

序号

No。

名  称

Name

型  号

Type

数 量

QTY

厂 家

Manufacturer

1

电子秤

Weighing system

TCS-150

1个

METTLER TOLEDO

2

控制器

Controller

IND131

1个

METTLER TOLEDO

3

走链

Conveyor

 

1套

自制

4

光电开关

Photoelectric Switch

BR400-DDT-P

3个

AUTONICS

5

气缸

Cylinder

SC80-500

1个

AIRTAC

6

电机减速机

Motor Reducer

0.4KW

1个

 

 

6.输送走链:

(1)全部进出桶走链均采用不锈钢链辊式走链,配套进出桶挡桶装置,根据三条线的启停状态及计数机构同时供给三条线的进桶和桶的输出。

(2)配套光电开关及可挡桶器,可根据桶的直径不同对光电开关进行调节,使桶居中运行,以便于适合不同桶型。

6. Conveyor chain:

(1) All inlet and outlet the conveyor chain adopt stainless steel chain roller chain, form a complete set of inlet and outlet blocking device, according to three lines of start-stop condition and counting mechanism at the same time supply three line into the keg and the keg of the output.

(2) The auxiliary photoelectric switch and the keg can be used to adjust the photoelectric switch according to the diameter of the keg, so that the keg can operate in the middle of the conveyor, so that it can be suitable for different kegs.

四.主机CIP刷洗方案:

清洗、灌装线主机的灌装头及酒管路在每次生产前后均需要做CIP刷洗,正常使用80-85度的热碱水和热水。本设备不另外配套主机自身的CIP刷洗系统,CIP由用户自行配套。CIP通过酒管路进入灌装头内,清洗酒管路和灌装头及相关管路。设备配套CIP的刷洗程序,在CIP程序模式下用户可进行CIP刷洗。因为设备刷洗所耗用CIP液数量较少,因此不配套碱回收管路,刷洗后的碱水及热水均排放处理。如果用户需要进行碱回收请提前说明。

D。 Host CIP cleaning scheme

The filling head and pipeline of the washing and filling line are required to be cleaned by CIP before and after each production, normally using 80-85 degrees of hot alkali water and hot water. The device does not have the CIP cleaning system of the host itself, CIP is provided by the user. CIP enters the filling head through the wine line, cleaning the wine pipeline and filling head and related pipeline. With CIP, the user can be scrubbed by CIP in CIP program mode. Because of the small amount of CIP fluid used in the cleaning of equipment, no alkali recovery line is used, and the alkaline water and hot water are discharged after washing. If the user needs to perform alkali recovery, please specify in advance.

五. 设备配置方案:

设备框架、管路、阀门、水箱等均采用标准SUS304材质;电器部件、水泵、检测元件、传感器等均采用高档配置。

E。 Equipment configuration scheme:

The equipment frame, pipeline, valve and water tank are all made of standard SUS304。 Electrical components, water pumps, detection components, sensors are all in high - grade configuration。

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