When considering a new filling system you should consider product pH levels (reference chart above). Second, you need to consider required shelf life, and filling temperature (hot, ambient, or cold). Lastly, look at your supply chain environments ie: refrigerated or ambient.
When you are working with microbiologically sensitive products it is tough to know if you should use Aseptic or Extended Shelf Life processing. With Fogg’s proven technology in Extended Shelf Life we are finding that more and more applications that were once ONLY considered Aseptic are now being filled with ESL lines. Please contact Fogg to discuss your specific application.
Fogg’s new sanitizing solution for your filling needs is our closed-looped Ultrazone O4® solution. The sanitization process can perform at a 3 – 6+ log reduction, turning your Fogg Filler into a near-aseptic machine or an add-on to a new Fogg filler.
A hydrogen peroxide like solution that is extracted from the water vapor and the air itself, keeps chemical cost low and increases profitability on your filling machine. Each package goes through a pre-treatment, sanitizing the bottle. During the sanitization process, the bottle can be sanitized on one or both turrets during the rinsing stage of the inside of the package.
The Ultrazone O4® solution comes complete with the Ultrazone O4® skid, which creates and recycles the solution. With the ability to reuse the water-based solution, one filler can save theoretically 18,000 gallons of water a day, increasing your facility’s savings on wastewater disposal.
ULTRAZONE WALKTHROUGH WITH BEN FOGG
HOT, COLD, ESL (Extended Shelf Life), and HPP (High Pressure Pasteurization)
As the juice market continues to grow, so do the demands for filling. Whether you fill hot or cold, Fogg has specific features to make your job easier.
While hot-filling, we know temperature management is always a concern. Fogg has created a unique temperature management system. A product evacuation tube inside your bowl will pump 5-50 gpm out of the bowl and send it back to the kitchen for re-work when line stops occur. The product never touches the atmosphere so it can be re-processed according to regulations. You can easily send more product that is at temperature directly into the bowl. This allows you to manage the temperature of the product inside your bowl with ease.
Sanitation is always a concern when filling, but it becomes extremely important while cold filling juice and other extended shelf life products (ESL). Because you can’t use heat to kill micro-organisms, you have to make sure to kill them before they ever come in contact with your product. Fogg offers a line of Microb-Blasters® to help sanitize. A Microb-Blaster® uses UV light or chemicals to kill micro-organisms to help ensure your product stays safe. There is also a CIP trough system, bottle rinsers, HEPA filtration, and a unique Sanibar® system the clean periodically between CIP cycles.
FRESH AND ESL OPTIONS (23-65 DAYS SHELF LIFE) AS OF APRIL, 2016, ALL DAIRY APPLICATIONS CAN CARRY THE 3A SYMBOL IF DESIRED
Fogg was one of the pioneers in the dairy industry. Throughout our experience we have heard the dairy industry’s concerns of foaming, possible flavor change, splashing and spillage, and extended shelf life. Fogg has created fillers to overcome these issues with ease.
Fogg has created a “dairy valve” to extract the foam while filling. Our small transfer ratio ensures smooth transfer to avoid spilling and splashing to increase sanitation and improve efficiencies. As always, shelf life is a concern. The dairy industry is beginning to push for longer shelf life than every thought possible. Some are requesting up to 60 day milk. Fogg has responded to these requests by offering an “Extended Shelf Life (ESL)” package. This package includes:
ALCOHOLIC AND NON-ALCOHOLIC, CARBONATED
We use a carbonated filling process to fill kombucha. The filling valves have a process of pre-evacuation to remove oxygen content from the containers prior to filling. It is not as sensitive as beer, but still very important in maintaining the quality of your product. As this industry grows Fogg will be there to help meet government regulations in the filling process, but still keeping true to the products great flavor and health benefits.
CUSTOMER TESTIMONIAL: BIG EASY BUCHA
BEER, WINE, SPIRITS, CHAMPAGNE. CARBONATED AND NON-CARBONATED LIQUIDS
Additional features Fogg boasts of are proven fill level consistencies, precise bottle control, explosion proof electrics, and simple valves for low maintenance. Fogg fillers are capable of filling multiple size bottles in PET and or glass. Just a few simple, color coded, change parts are needed for quick, efficient change over. In addition to a Fogg filler you have the option of a wide range of capping turrets to accommodate your unique packaging.
Wine can also be filled on a Fogg. Wineries prefer Fogg fillers over others because of their smooth bottle handling, filling accuracy, and product recovery system. A corker or ROPP capper can easily be integrated.
CUSTOMER TESTIMONIAL: HIGH WEST DISTILLERY
STILL LIQUIDS, IRRIGATION FLUIDS, COUGH SYRUPS
The pharmaceuticals industry has already taken advantage of Fogg’s unique filling process for many different flowable products. Fogg’s success ranges from surgical irrigation fluid, prescription oral debriding agent, to embalming fluid. Although not recommended for injectables, there are many applications where Fogg excels.
With class 10 or 100 HEPA units for filtering the filling environment and machine guarding to fight against any unwanted elements this is the best way to go. Often people claim they need aseptic, but Fogg has often times shown customers how to meet their requirements with out spending the extra money for an aseptic machine.
Precision is the key when filling very expensive pharmaceuticals. With Fogg’s special valves the accuracy of the fill height is imperative. Knowing the fill height is exactly the same every time can give the customer confidence in their rate of return. Fogg’s long term commitment to quality equipment and 24 hour support has attributed to mutual success!
STILL AND CARBONATED, FLAVORED OR NON-FLAVORED, HIGH PH
A majority of the water industry is or has moved from 28mm to 26.7mm caps so Fogg has designed a capper to effortlessly cap. And as always, Fogg upholds the highest level of sanitation to ensure your water or water based product is always at its optimum flavor and shelf life.
Fogg is known for its ability to customize their filling systems to specific applications. As new packaging materials and new products are created Fogg is continually changing to meet the demands.
JUST A FEW OF THE UNIQUE PRODUCTS WE HAVE FILLED:
Salsa / Irrigation fluid / Embalming fluid / Lantern fuel / Honey / Chocolate syrup / Fuel injector cleaner / Aloe juice / Cannabis Cocktails