If you are looking for an alternative to aseptic filling for high-acid products, the solution is Hot Fill.
Galdi's configuration is particularly suitable for packaging fruit juices and products with a pH lower than 4.1 and a shelf-life of 8 to 12 months.
Indeed, Hot Fill offers an effective alternative to aseptic filling, delivering the same results as well as some additional benefits.
First, it helps clients to significantly reduce both their initial investment and servicing costs throughout the machine lifecycle.
In addition, the configuration allows the same machine to be used for different formats, switching from small to big and vice versa in only 3 minutes.
What's more, Hot Fill removes the need of a cooling system after pasteurization, as the product is pasteurized right before reaching the filling machine – yet another cost saving!
With Hot Fill, the product is packaged directly into the carton at a temperature ranging from 80°C and 90°C. The carton is therefore sterilized by the liquid's heat, with no added systems required.
After the filling, the carton is subject to a thermal treatment during which the product's temperature is dropped using a cooling tunnel.
Cartons are cooled externally through low-temperature water sprays, leaving the machine at room temperature and in suitable conditions for stocking.
In case of machine downtime for external causes or plant slowdown, the Hot Fill technology keeps the product in motion, maintaining it at the same temperature and preventing spoilage or cooling.
During machine idle time, the liquid remains in the tank, at least until the temperature control system indicates out-of-range values on the client display. In this case, the machine quickly releases the product and sends it back for reprocessing.
Our Hot Fill machines are also designed to guarantee the carton's maximum resistance and strongest protection against oxygen permeability.
Each Galdi machine is tested through hot filling at our premises before delivery, so as to carefully check that cartons are properly sealed.
Indeed, in dealing with products with a long shelf-life, every carton must be perfectly sealed leaving no room for mistakes.
Like Warm Fill, Hot Fill requires cartons with an inner aluminum layer, given the high level of acidity of the products. The filling speed ranges from 2000 to 5000 cartons per hour.