Aseptic bulk bag filling
An aseptic filler fills prepared containers with sterilized product under controlled aseptic conditions. The filling system must be suited to the process and packaging.
Discuss your filling requirements
Our aseptic fillers are intended for bulk filling into aseptic bags. We offer a model that supports aseptic bag-in-bin, bag-in-drum and 20 L bag-in-box formats on the same machine.
The bag type, bag connection and supporting container are specified for each project.
Muninmax can configure an aseptic filler to handle bag-in-bin, bag-in-drum and bag-in-box formats on the same machine. The equipment arrangement is selected for the formats and operating requirements involved.
Drum and bin filling require an X-Lift. For drum filling, the X-Lift raises the drum to prevent excessive tension on the bag during filling. An Autofeed Bag System uses web bags, supplied as a continuous series of connected bags.
Compare the intended use and equipment arrangement for each configuration.
| Intended use | Equipment arrangement |
|---|---|
| Bag-in-drum only | Include an X-Lift to raise the drum during filling. |
| Bag-in-box only | An X-Lift is not required and can be omitted. An Autofeed Bag System can be considered according to the operating requirements. |
| Drum and box | A small X-Lift can be used. An Autofeed Bag System can be added when box-filling volumes justify it, while avoiding the cost of a Big X-Lift where it is not needed. |
| Mainly drum filling, with a limited amount of box filling | Use the aseptic filler with an X-Lift and feed the bag-in-box bags manually. |
| Bin, drum and box | Select a Big X-Lift for the bins, which can also handle drums. An Autofeed Bag System can be added where box-filling volumes justify it. |
The selected equipment and options are defined for the machine and project. Each configuration should be discussed against the intended bag formats and operating requirements.
Discuss your filling requirements
Our aseptic filler uses steam together with hydrogen peroxide (H₂O₂) within the filling chamber as part of its sterilization system. During cap sterilization, the temperature inside the filling chamber does not exceed 100°C.
Process-authority testing has been carried out for a customer application. Supporting documentation is retained by the customer for audit purposes.
Under the operating conditions assessed, we have observed reduced visible steam plume and condensate compared with higher-temperature steam operation.
Our aseptic fillers can connect directly to a UHT system or to an aseptic tank, depending on the product, process and project requirements.
We design and fabricate our aseptic fillers in-house from stainless steel sheet and tubing. We also specify and source the associated equipment and components.
The filling system and its connections are designed around the product, packaging and project requirements.
Our services cover design, manufacture, procurement, installation, commissioning and after-sales service. Included work, optional items, exclusions and each party’s responsibilities are defined in the project proposal and agreement.
The machine and associated equipment are supplied according to the agreed delivery scope. Testing and acceptance criteria are agreed for each project.
Performance guarantees are agreed in writing for each project. They specify the guaranteed values, raw material and operating conditions, test methods and acceptance criteria.
Provide the intended bag format, bag connection and supporting container when discussing a format change. The required arrangement is assessed for the particular machine and packaging combination.
A supported format does not mean that every bag size, connection or spout position can be used without adjustments. The applicable parts and changes are determined for the machine being considered.
Describe whether the filler will receive product directly from a UHT system or from an aseptic tank. The product, packaging and connections are considered together within the project scope.
The single-head arrangement includes preparation, filling and CIP sequences, with operator involvement in setup and starting operations. The filling head can be adapted for bag caps up to 2 inches in size. Product-piece suitability is assessed with the product path and selected filling configuration.
| Item | Configuration |
|---|---|
| Filling arrangement | Single-head aseptic bulk bag filling |
| Bag cap adaptation | Up to 2 inches |
| Design and capacity | Defined by the project design criteria |
| Capacity selection factors | Bag size, product supply facilities and operator handling |
| Filling measurement | Electromagnetic or mass flow meter, or load cell, according to the design criteria |
| Product-contact metal parts | AISI 316L stainless steel |
| Machine controls | PLC and HMI included |
| Additional controls and system integration | Separate options |
| Electrical requirements | Specified according to the selected functions |
The reference head arrangement provides clamps for 200 L or 1,000 L bags according to the configuration. Its roller conveyor has a 0.37 kW geared motor, and the hydraulic X-Lift system has a 1.1 kW rating. These are component ratings for that arrangement.
An automatic bag-feed system for connected web bags is an option. Preparing the first bag of each carton still requires operator action. Bag formats, clamps, lift arrangement and automatic feeding are selected together for the intended operation.
The following values describe the single-head reference configuration. Final utility requirements follow the selected equipment and operating functions. Pressure values marked kPa(e) are gauge pressures.
| Utility | Reference requirement |
|---|---|
| Steam pressure | 500–700 kPa(e) |
| Steam back pressure | No more than 100 kPa(e) |
| Steam consumption per head | 16 kg/h during filling; 40 kg/h during sterilization |
| Compressed air pressure | 600–800 kPa(e) |
| Compressed air dew point | No higher than −3°C |
| Compressed air flow | 2 m³/h per head |
| Reference electrical supply | 380 V / three-phase / 50 Hz |
| Chilled water | 1 L/min at 1 barg and 7–15°C per head |
| Process-water quality | Drinking-water grade |
| Process-water supply | 300–400 kPa(e), 20–35°C |
| Process-water flow during start-up and SIP | 8 m³/h |
The steam rates describe different operating phases. Water required during start-up and SIP is identified separately from continuous production use. Cleaning connections are designed around the customer's central CIP supply.
Drum and bin filling require an X-Lift. For drum filling, the lift raises the drum to avoid excessive bag tension. An Autofeed Bag System uses connected web bags.
| Intended formats | Arrangement to discuss |
|---|---|
| Bag-in-drum only | X-Lift for drum filling |
| Bag-in-box only | X-Lift can be omitted; Autofeed can be considered |
| Drum and box | Small X-Lift; Autofeed where box-filling volumes justify it |
| Mainly drums with limited box filling | X-Lift with manual bag-in-box feeding |
| Bin, drum and box | Big X-Lift for bins and drums; optional Autofeed for box filling |
A supported format does not mean that every bag size, connection or spout position can be used without adjustments. Equipment and changes are defined for the selected machine and packaging.
The filler can receive product directly from a UHT system or through an aseptic tank. Product, packaging, tank connections and control integration are considered together.
Share the product and particle characteristics, bag size and connection, supporting container, product supply and required filling rate. Include the intended tank connection and control integration.
Address: 107/1 Moo 5, Wang Phong, Pran Buri, Prachuap Khiri Khan 77120, Thailand.
Describe the product, packaging and filling requirements. Where known, share:
Start with the information available. The machine, packaging combination, options and acceptance criteria are discussed for the project.
