A wide variety of layouts are possible with the SpectraPak 3000 Bottling system as well as the various water treatment equipments and blow molding assemblies which can be assembled in a production environment.
Shown below is one example of how the "clean room" might look for a combination of the SpectraPak 3000(1/2 liter to 1 gallon) and the smaller volume, Large-Format(3 or 5 gallon) bottling equipments.
Notice that the Filling Systems for both large and small format assemblies are located in the clean room area while the washer for the large format system, the blow molder(s) and all water treatment equipments are located outside of this "clean room".
The Clean Room should be operated under a "positive air pressure" environment which ensures that no external airborne particulate or organic contaminants are pulled into the operating area. This is normally accomplished by the use of an external air filtration system feeding clean air into the clean room, thus providing the "positive pressure" environment necessary to maintain a sanitary work envirnoment.
Notice the various personnel required to man the various components of the systems. Since two types of bottling formats are involved in this particular layout, you will notice that a separate individual is responsible for the BW60 Bottle Washer. This same individual, after washing the abottles in the BW60, follows the clean bottles into the Clean Room and fills them at the BF150 Bottle Filler. They then leave the room on the 5' roller conveyer.
For the Small Format process, three individuals are ideally required although two can operate the entire system if certain conditions are met. Depending on the size of the accumulation(output) conveyor and the type of bottle loading device(i.e. 48" round feed table) for the SpectraPak 3000, two people could handle the job quite easily.
As noted on this first diagram, in this example the water purification and treatment equipments are located to the left of the clean room. A separate diagram follows for that area. Variations of that area are possible, depending on whether a steam distillation or reverse osmosis or spring water source is used for the bottling process. See that area for details and discussion.
The BlowMolding equipments(if used) sit next to the feed line for the SpectraPak 3000. Bottles are coming off the BlowMolding equipment at about 5 times slower than maximum speed of the SpectraPak. For example, if 1/2 liter bottles are being blown and filled, 600 bottles per hour are produced by each BM600 Blow Molder. Meanwhile, the SpectraPak 3000 is running at 3000 bottles per hour(maximum) providing no down time is allocated. This means that either several BM600 units must be operated in parallel or the SpectraPak unit runs only a few hours per day to accommodate what can be produced by the ensemble of BM600 units.
If the SpectraPak system is running 1.5 liter bottles, its maximum filling speed will be approximately 2000 bottles per hour. The BM600 is still running at 600 bottles per hour and the ratio of bottle production to filling is reduced to about 1:3 versus 1:5 as in the above example for 1/2 liter operation.
It is wise to allow plenty of room around all of the operating components for maintenance and washdown. Do not crowd the assemblies against walls or other obstructions for safety as well as operational reasons.
A full, on-site installation and personnel training is available anywhere in the world with this system. It is a necessary expense that should not be overlooked for these equipments.
A laboratory area is highly recommended to accommodate various types of testing equipments which are necessary for this type of bottling operation. These equipments include: bacteria Test Kit w/incubator; Chloride and Chlorine test kits; Conductivity(Total Dissolved Solids) testor(s); Detergent Test Kit, Hardness Test Kit(for water conditioner monitoring), Ozone Pocket Colorimeter or other Ozone concentration test kit; and pH meter. Also in the lab would be your detergents and other sanitization products to maintain sterility for the bottling line(s).
>Scaled-down Small-Format Bottling Operation Layout >
> >Water Equipment, Small Format Bottling and Blow Molding Area Layouts HERE
>Hybrid Small and Large Format Bottling Operation Layout HERE.
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