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This combishape system is provided by Sig Combibloc. The uniqueness of this system lies in the fact that the aseptic beverage packaging it processes is free from the common rectangular square structure. According to Sig Combibloc, combishape can process more than 40 different shapes of sterile bricks, each with its own characteristics. CAPSA was the first company to put the system into commercial production. They chose oval aseptic packaging, and the system can also adjust the specific dimensions of ovals according to customer needs.
CAPSA began to introduce this new packaging product in March last year. The reason why the company wants to introduce a brand new packaging form is to maintain its leading position in the fierce market competition with the help of unique packaging.
“Combishape not only helps us occupy the market with unique packaging, but also represents a revolution in aseptic packaging.†CAPSA President Pedro Astals said, “In the future, whether a brand can survive depends on whether it can guarantee the quality and correctness of its products. Market judgement combined."
CAPSA's NaturLinea is also a brand new product. It contains a special Tonalin® ingredient extracted from safflower that reduces the body's fat structure and converts existing fats into energy. CAPSA is the only company in Spain that offers similar products. Therefore, special shaped aseptic brick packaging can strengthen the unique effects of the product. As CAPSA claims: Packaging the most innovative products in state-of-the-art packaging.
The difference between the combishape and other Sig Combibloc aseptic systems is that in the past these systems either used a single reel material or filled aseptically processed aseptic tiles. Combibloc combines the side, bottom and cover sections of the bricks on three separate roll feeders. All three parts are made of paper/aluminum foil/PE construction.
Four parts
The aseptic brick forming and filling system consists of four parts: sealing device, brick molding device, transfer device and filling device. The sealing device adopts a two-step design: first, a round hole is punched on the cover surface, and then the lid joint part is sealed along the opening. The joint is injection-molded with polyethylene and has a diameter of 30 mm.
The brick molding device collects the sealing, bottom material and side material. The first step is to complete the seal, then cut a section of the material from the coil as a brick body, using heat and pressure to form the brick bottom that is also sealed to the brick using heat and pressure.
The transfer unit feeds the shaped sterile bricks into the discs, which feed the sterile bricks to a loading device that places an aluminum foil on the closure. The sterile brick after this step is completed will enter the disinfection/filling/sealing device.
The entire aseptic brick processing and molding process uses continuous operation, while the filling is intermittent and takes place in a sterile environment. First, the aseptic brick was blown open and pre-heated and then blown open and preheated once. The system infuses hydrogen peroxide into sterile bricks and then dries them. After that, the filling process is completed. After completion, a layer of aluminum foil is heat-sealed at the lid and the entire brick is completely closed. Afterwards, sterile bricks are sent out of the sterile area. According to Sig Combibloc, the filling rate is about 165 packs/minute.
The sterile bricks on the conveyor belt are fed into the next conveyor belt by the mechanical device and can simultaneously grab 8 bags of sterile bricks at a time.
Then only the stamping and packing steps are left. The capping machine uses Alcoa's 9-station capping machine. The covered sterile bricks 12 were sent to 4 trays in batches, and 3 trays were placed on each tray. After repeating the 12-pack stacking again, there are 6 sterile bags per tray on the 4 trays. Then it entered the shrink packaging machine. A plastic handle was added to the shrink wrap for easy carrying by consumers. The processing equipment for this handle is Condi Film. The stacking system is supplied by Ocme.
With such a large and complex system, the installation process can be troublesome to think about. What's more, it is the first time that a new system has been put into commercial use?
Javier Echevarria, CAPSA's director of industry and technology, said, "We are primarily concerned with maintaining the sterile environment, but from the start of system testing, the aseptic environment has remained very good and there have never been health problems."
Echevarria said that both retailers and consumers love the combination of this new product and packaging.
“We have a perfect combination of a brand new product and unique packaging. It is fully equipped to achieve success.â€
Aseptic bricks new image
The aseptic filling of paper and foil containers has long been no surprise, and high-speed paper cup processing technology has also been implemented, but the combination of these two technologies is rare. Spain’s CAPSA completed this myth. The company’s 1L milk aseptic packaging uses both technologies and is very handy.