GEA Launches ABF 2.0 Filling System For Shelf-Stable, Sensitive Beverages And Milk-Based Drinks

Wednesday, June 17th, 2020 | 1655 Views

The new rotary Aseptic Blow Fill technology from GEA (ABF 2.0) provides beverage manufacturers with maximum hygiene and food safety and top performance in terms of filling speed, accuracy and flexibility. ABF 2.0 is suitable for the filling of shelf-stable, sensitive beverages and milk-based drinks, using H2O2 for the sterilisation of PET preforms.

With the ABF 2.0, GEA has used all its experience to optimise Total Cost of Ownership (TCO) while enhancing the control of key parameters to eliminate any potential risk to the product. The ABF 2.0 can fill a full range of sensitive beverages including still, clear drinks with or without particles, and carbonated drinks – high or low acid.


New features for efficiency and control

The new ABF 2.0 is an evolution from the original that includes many mechanical improvements and simplifications. These reduce power consumption while eliminating any potential risk of contamination by ensuring that every step of the sterilisation process is carefully planned, controlled and properly managed. Every process parameter and critical point is carefully monitored and traced to ensure reliable and repeatable sterilisation performance. As an additional guarantee of reliable and efficient sterilisation treatment, a Smart Sensor monitors spraying performance at each sterilisation nozzle. This helps to guarantee the safety and quality of the final product, with the speed, accuracy and flexibility customers want.

Unlike the original machine, the preform does not need to be turned along the transfer to the aseptic blower: this saves time and reduces maintenance costs. A new oven withmilk optimised materials allowed to have fewer heating modules, this has achieved a significant reduction in power usage and the overall oven footprint. The introduction of an air recovery system in the blowing module has reduced power usage in that area as well. These innovations combine to provide users with a noticeable reduction in TCO.

The aseptic blowing wheel is located within the sterile zone with the filling and capping processes. This means that the sterile container does not leave the sterile area until the filling and capping is complete. This rigorous aseptic process ensures that the environmental contamination level is always under control.

The bottle caps are sterilised using Sterilcap VHP R from GEA. This is unique technology that provides gentle sterilisation treatment at reduced temperature to avoid overheating the caps and includes a buffer to optimise the Overall Equipment Effectiveness (OEE) of the line.



Most bottling plants handle a wide variety of products so GEA has designed the format changeover system on the ABF 2.0 to be fast and simple. This has enhanced the flexibility of the machine so that it appeals to the widest range of customers especially those with multiple products. As companies work to achieve market share and product variety, the flexibility of plant operations is vitally important. Furthermore, being the evolution of a consolidated, FDA validated platform, the ABF 2.0 is ready to meet all FDA regulations, which represent one of the most stringent protocols.


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