MOVING IDEAS

Filling systems in the

beverages industry
Filling and bottle treatment technologies for bottling water,
soft drinks, spirits and other products of the beverages industry

Text by Manuel Bolzoni, Gabriele Folli, Glauco Cima, Carlo Nucci, Ermes Battistini

OCME Competence Library

www.ocme.com

Machine series

OCME designs, manufactures and installs filling,

packaging, palletising and handling machines for
all the major mass consumer product manufacturing
sectors. OCME machines are the result of decades of
experience and are designed to become the backbone of
our Customers production division.

High and low level

depalletisers

DORADO
ANTARES

Roll-fed labeller

SAGITTA

Level filler for beverages

HYDRA

In-line and rotary

volumetric fillers

LYNX

In-line and rotary weight

fillers

LIBRA

Shrink-wrap and tray-packers

VEGA

Wraparound packers

ALTAIR

Combined wraparound and

shrink-wrap packers

GEMINI

High and low level

palletisers with 90 infeed

PERSEUS

In-line high and low level

palletisers

ORION

Robot palletisers

PEGASUS

Automated guided vehicles

AURIGA

Computerised control system

ALBATROS

Filling systems in the

beverages industry
Filling and bottle treatment technologies for bottling water,
soft drinks, spirits and other products of the beverages industry

Contents
Filling bottles for tomorrows consumers

Filling systems: comparing technologies

Comparing technologies

Which products to handle

Hydra and Libra fillers: the machines in detail

Hydra, level and flow meter fillers

12

Features shared by all Hydra models

19

Libra R5: electronic weight filler

20

Libra R5 for spirits

22

Libra R5 for 5 gallon bottles

23

Hygiene and safety for food products

24

The ideal plant in the beverages industry

28

Complementary machines for the filling line

30

The marketing value of filling machines

33

Environmental respect

34

OCME Competence Library

www.ocme.com

Filling bottles for tomorrows consumers

....Good ideas alone are not enough;

you also have to know how to package them.
Anonymous

n a literal sense, filling is no more than the task carried out by a

machine that packages liquid products such as drinks or water.
Nonetheless, for modern-day companies, the apparent simplicity
of this phrase hides a plethora of variables and possibilities
that embrace all the types of containers and caps and all the materials used in
their manufacture and the nature of the product to be filled,
as well as by no means secondary aspects associated to
productivity, precision, overall cost of the filling technology
and the environmental impact of the production sites.
Today, more than ever before, the beverages market offers
opportunities that may be seized only by companies that
have the technology it takes to keep them one step ahead
of the competition. The birth of new types of products, the
growth of the private brand market and the need for constant
differentiation (in terms of both packaging and format)
demonstrate that a high degree of flexibility is a priority.
Essential conditions to render flexibility a real advantage
are efficiency and the total availability of the bottling line.
Its easy to think of a filling machine as the sole, nerve
core of a system, but in actual fact, every machine located
upstream and downstream is just as important, and the
perfect coordination between the wet area and the dry
area, including all the plants internal logistic issues,
determine a companys real capacity to fulfil customer requests. Paraphrasing a
basic marketing rule, one could say that the companys task, and therefore the
manufacturing technology used by the company, no longer ends with a filled and
capped bottle, but rather with a sold and appreciated bottle, hence maximising
commitment and results.

OCME: Filling systems in the beverages industry

Filling systems:
Comparing technologies

A bottle is filled when the

liquid is transferred from the
tank to the container itself.
That which distinguishes
one filling technology from another is the way
in which the correct quantity of product is
supplied.
Different systems and different technologies
may be used. Principally, these may be divided
into three categories: filling by level sensing,
using volumetric flow meters and by weight.
Of these three systems, the level sensing
system is consolidated by years of use in the
beverages sector, as it is predominantly tied
to mechanical devices. Ocme machines for the
beverage industry use both level technology
and electronic weight technology or volumetric

flow meters.
In the latter two cases, a sensor (which may
either be a scale with a load cell or a mass or
magnetic indicator, depending on the technology
used) enables or interrupts the flow of product
towards the bottle, so as to obtain the correct
amount of product inside the container, based on
the production settings.
Industry literature provides for another type
of filling machine, belonging to the volumetric
family, known as a piston-filler. These are
prevalently mechanical machines into which a
given volume of product is transferred by means
of the action of a piston.
Seeing as this type of technology is not important
in the beverages sector, it will not be dealt with in
this brochure.

Comparing technologies

By level sensing
These are the most traditional and
commonly used types of filling machines.
The fill level is determined by the length of
the tube that enters the bottle, during the
filling stage. Generally speaking, to change
the level in the bottle, the tube must also be
changed.

By flow meters
These types of filling machines
measure the volume of the product
entering the bottle. A flow meter (with
either a mass or magnetic indicator)
fitted on every filling nozzle gauges the
volume. These are called electronic
filling machines.

By weight
This type of filling machine
measures the weight of the
product entering the bottle, after
having taken the tare weight of
the container. A load cell for each
filling valve measures the weight.
These are electronic machines par
excellence.

By level sensing

By volumetric flow metre

By weight

Precision

Variability based on
ambient conditions

Maintenance

Format change

Ease of sanitisation

Key:

+ = positive

= = neutral

- = negative

OCME: Filling systems in the beverages industry

Which products to handle

he Ocme series of filling

machines consents choosing
the right technology to handle
a vast number of products,
both strictly for beverages as well as for other
food liquids of various types.
To choose the ideal machine, various factors
must be considered, such as for example, the
type of product, the type of container and the
material used for the container, but also the
degree of precision required and the production
volume.
The Ocme series of machines is designed to
cover a wide range of possibilities, allowing
companies in the beverages sector to cover
everything from small or medium production

volumes to large or very large volumes.

Along with the Hydra machines, specially
designed and built to meet the needs of
companies in the beverages sector, Ocme also
offers the Libra series of filling machines, which
derive from the high production and efficiency
filling systems used in other consumer goods
industrial sectors.
These latter machines, the Libra series, are
used for large scale productions of gallon
bottles containing still water (bottles containing
up to 10 litres), or as a weight-based alternative
to volumetric filling for the spirit and wine
sector, where the high value of the product
makes the Ocme high-precision weight system
technology particularly appealing.

Hydra and Libra fillers:

The machines in detail

Here below is the list of the range of OCME

filling machine models for the beverages
industry.
HYDRA N
Filling for still liquids. This filling machine
is a mechanical type machine and uses
the level filling system. Gravity filling
by atmospheric pressure. The machine is
equipped with an annular tank and has an
extremely rational design. The presence of the
bottle opens the valve. The machine is easy to
sanitise thanks to a series of devices studied
especially for this purpose.
HYDRA I
Filling for still and carbonated liquids; may
also be used for still products alone. Ocme
has designed this type of filling machine
by combining leading-edge electronic and
pneumatic technological solutions.
Hence, this is a level filler that may be classified
electro-pneumatic.
To handle carbonated products, the product

tank must be pressurised, but this machine

may also handle still products and, in this
case, it works at atmospheric pressure. The
machine is equipped with an annular tank
and is mechanically and structurally built in a
simple and rational manner. The machine uses
the same sanitising systems as the Hydra N
machine.
HYDRA I-AR
Filling for carbonated products; may also be
used for still products, with separated air
return system in order to eliminate any risk
of contamination. It has the same design
characteristics as the Hydra-I machine, with an
added separated air return circuit that prevents
contamination hazards and avoids having to
introduce nitrogen or sterilised air into the
filling circuit.
The separated air return system consents
filling for still products without the need
to pressurise, hence avoiding the risk of
deforming the container and therefore
permitting the use of thinner-walled bottles.

10 OCME: Filling systems in the beverages industry

HYDRA N-V
Filling for alcoholic products (spirits, etc.). This
type of filler has been designed by combining
electronics and pneumatics. It may be defined
as an electro-pneumatic control machine that
works by level. This filling method is carried
out by taking advantage of a slight negative
pressure in the tank, hence providing the
following advantages:
allows for auto-level in the bottle and
hence for very precise fill levels
the slight negative pressure means that not
even a drop of product is wasted
independent vacuum management for each
filling valve
The latter two characteristics are extremely
appreciated when filling expensive products.
Moreover, this method consents varying the
level in the bottle within a 25 mm range
without having to change the filling spouts.

HYDRA M
Rotary filler with a flow meter (either magnetic
or mass, depending on the application). This
machine is manufactured with a minimum of
32 valves and up to a maximum 120. It is suited
to filling any size or shape bottle, either glass
or PET, with extreme volumetric precision.
Production output from 8000 bph to over
100,000 bph. Suited to filling still products at
room temperature or hot.
LIBRA R5
Electronic rotary weight fillers designed to fill
still liquids. Typical applications for this type of
machine include filling 5-10 litre natural water
bottles at high output speeds and filling spirits.

11

Still products
Machine
model

Type of product

Number of
nozzles
(from... to...)

Container
types

Container
formats

Technology
used

Speed
(referred to a 1.5 l PET
still water container)

Maximum speed
reached

Hydra N

Still water, Wine,

Non-carbonated
drinks

32-120

PET, glass
bottles

from 0,25 to
2,5 lt

Gravity
level filling

10.000 50.000

100.000

Hydra M

Still water, Juices,

Non-carbonated
drinks

32-120

PET, glass
bottles

from 0,25 to
2,5 lt

Flow metre
filling

10.000 50.000

100.000

8-42

Large
containers (i.e.
5 gallons PET
bottles)

from 5 to 10 lt

Electronic
weight
filling

1.500 12.000 *

12.000

Libra R5

Still water

* Speed referred to a 5 litre still water container

Carbonated products
Machine
model

Type of product

Number of
nozzles
(from... to...)

Container types

Container
formats

Technology
used

Speed
(referred to a 1.5 l PET
still water container)

Maximum speed
reached

Hydra I

Carbonated and
flat water, beer,
carbonated drinks,
still wine, sparkling
wine, drinks with an
alcohol content

32-120

PET, glass
bottles

from 0,25 to
2,5 lt

Isobaric
level filling

6.000 50.000

100.000

Hydra I-AR

Carbonated and
flat water, beer,
carbonated drinks,
still wine, sparkling
wine, drinks with an
alcohol content

6.000 50.000

100.000

from 0,25 to
2,5 lt

Isobaric
level
filling with
separated
air return

32-168

PET, glass
bottles

Number of
nozzles
(from... to...)

Container types

Container
formats

Technology
used

from 0,25 to
2,5 lt

Gravity level
filler with
8.000 40.000
slight negative
pressure

50.000

from 0,25 to
2,5 lt

Electronic
weight filler

40.000

Spirits
Machine
model

Type of product

Hydra N-V

Spirits

32-120

PET, glass
bottles

Libra R5

Spirits

16-84

PET, glass
bottles

Speed
Maximum speed
(referred to a 0.75 l glass
reached
container)

3.000 30.000

12 OCME: Filling systems in the beverages industry

Hydra, level and flow meter fillers

he Hydra series of
machines comprises
fillers that have been
specially designed for the beverages
industry. The design was born to permit
the integration of high-performance and
high-flexibility machines into the already
vast range of Ocme solutions for the
beverages sector.
Hydra is a series of fillers that have been
designed to handle a wide variety of
products, bottles and production speeds.
Starting from the two standard models,
Hydra N for still liquids and Hydra I for
still and carbonated liquids, the series
includes machines with from 32 to 168
filling valves for a production output that
ranges from 12,000 to 100,000 bph. The
isobaric version is also available in the
Hydra I-AR configuration, with separated
air return.

The pitches used for bottle handling

allow for great flexibility and, most of all,
enable adapting the machine to the type
of production required by the customer.
Pitch ranges are:
94 mm for bottles max 89 mm;
113mm for bottles max 108 mm;
126mm for bottles max 120 mm;
141mm for bottles max 130 mm.
Lastly, Hydra M is the series of beverage
fillers designed for still liquids and
equipped with flow meters, with 32 and
120 filling valve models, for a production
output range between 12,000 and
100,000 bph.

Figure 1
Passing starwheel between the
filler and the capping machine.

Figure 2
Filling carousel with bottle lifters
for glass bottles.

Figure 3
Capping machine for glass bottles.

Figure 4
Starwheel for filler infeed.

13

14 OCME: Filling systems in the beverages industry

HYDRA-N
Gravity level filling valve

HYDRA I
Isobaric level filling valve

A
B

C
A Separated air return
channel

A Upper electropneumatic valve

B Membrane

C Tank
D Separated air return
pipe

E Filling valve
F Deflector
G Air evacuation pipe

C Tank
D Spring
E Filling valve

B CO2 counterpressure

F Lower electropneumatic valve

G
H

G Deflector
H Air evacuation pipe

Hydra N
The HYDRA-N filling valve: efficiency and hygiene
The task of the filling valve is to transfer the correct quantity
of product into the bottle, as quickly as possible, in the most
hygienic manner possible and with the greatest possible
precision, reducing maintenance and sanitisation needs
to a minimum. The valve fitted on Hydra machines comes
from a well tested technology available on the market, with
important improvements applied by OCME as to reach an
average speed of 375 ml per second (for 1.5 lt bottles).
One of the great advantages provided by this level of
performance is that 40 valves are sufficient on a machine that
outputs 14,400 bph (1.5 l bottles); competitor solutions require
many more filling heads, with the obvious disadvantage of a
greater initial investment and higher maintenance expenses
in the future. The incredible average filling speed (that in
some installations is generally even being surpassed) is
ensured thanks to the unique design of the valve, which

reduces turbulence during the filling stage. Mechanically

speaking, the valve is very simple: it is composed of very
few elements, has no dynamic gaskets (sliding during the
opening-closing stage), drains perfectly (does not contain the
usual 9 cc drop of liquid) and wear is practically non-existent.
It has been designed specifically for highly hygienic filling.
For still water filling, air is evacuated from the bottle through
a separate pipe, with no risk of contaminating the main
product tank. Parts coming into contact with the product may
be manufactured in stainless steel 316 or in a special food
grade rubber that is resistant to aggressive treatments (ex.
ozonated water, hot CIP cycle, acid additives, etc.).
Quick valve disassembly
Disassembling the filling valves is extremely fast and easy;
just loosen a screw by half a turn to remove two valves
simultaneously.

15

7 HYDRA I-AR
Isobaric level filling valve with
separated air return
A
B

A Upper electropneumatic valve

B Separated air return
channel

Stage 1 Bottle lifting

A mechanical cam lifts the bottle lifters and pushes the bottles
towards the centring bell. The push force exerted by the bottle
lifter allows the bottle to remain sealed on the valve.

Stage 2 Bottle pressurisation and/or fluxing

The bottle is then pressurised using CO2 by acting on the
electronic control of the upper block so that the counterpressure chamber and the inside of the bottle to equalize.

C CO2 counter-pressure

D Tank
E Spring
F Filling valve

H
I

G Lower electropneumatic valve

H Deflector
I Air evacuation pipe

Stage 3 Filling
The product begins to flow inside the bottle as soon as the
bottle reaches the same pressure as the counter-pressure
chamber (isobarometric condition). The air contained inside
the bottle is evacuated through a tube on the lower part of
the valve. Product flow is controlled by a deflector inserted
in the external part of the tube, in order to avoid turbulence
and foam which may be detrimental to proper filling. Filling
is complete when the product level reaches the lower part of
the tube, cutting off air return.
Stage 4 Closing
Once filling is complete, an electronic signal enables closing of
the block section dedicated to pressurisation.
Stage 5 Decompression
The pressure inside the bottle is gently released through the
lower block and evacuated through a centralised manifold.

Hydra I
Isobarometric filler with electro-pneumatic
control system
The valve is designed in blocks with minimal parts, for
extremely easy and limited maintenance interventions.
The blocks are independent from one another, to facilitate
disassembly and/or replacement.
The upper block comprises the electro-pneumatic drives
that control pressurisation, filling and closing.
The central block comprises the valve body, with the
spring, siphon, central stem and tubes for air return.
The lower block comprises the electro-pneumatic drives
that control decompression (single or, on request, dual).
The carbonated liquid filling stages, PLC-controlled by setting
the specific recipes are summarised below:

Stage 6 Bottle lifter lowers

Once atmospheric pressure has been reached, the bottle is
accompanied to the height of the starwheel for transfer to
the capping machine.
For format changeover, simply select a different recipe from
the Operator Panel and, if necessary, substitute the tubes that
regulate the level in the bottle.

Hydra I-AR
Upon customer request, a separated air return may be added
to eliminate any risk of contaminating the product in the tank.
With this modification for non-carbonated products, filling
will be carried out by gravity without the aid of a slight overpressure. The PLC controls the upper block for valve opening
and closing without counter-pressure. In this case, stages 2
and 5 are completely eliminated, facilitating the use of lightweight, flat-bottomed preforms.

16 OCME: Filling systems in the beverages industry

Hydra N-V
Hydra for spirits
(slight negative pressure, for glass bottles)

At this point, the bottle lifter may lower and the bottle
exits the filler.

Operating principle
This machine derives from our Hydra filler for still
liquids. The only variation required was the addition of a
pneumatic actuator on the upper section of the tank that
operates the open-close control for the air return pipe
of every head.
The bottles incoming to the filler are positioned on the
disk of the bottle lifter which, once released from the
cam, pushes them against the rubber seal and then,
continuing its stroke, opens the liquid valve.
Filling begins when the pneumatic actuator opens the
air return, so that the slight negative pressure reaches
the bottle.
Once the bottle has been completely filled, the
automatic-levelling stage begins, by detaching the
bottle from the head by a few millimetres, thanks to the
slight negative pressure.
The filling cycle ends when the pneumatic actuator
transmits the close command, while the flow of liquid is
closed, detaching the bottle from the head.

Technical features
The main feature of this filler is that it operates by
means of a slight negative pressure that is applied to
the tank, is transferred to the heads and reaches the
bottle during the filling cycle.
Slight negative pressure
Note that the slight negative pressure in the tank and in
all the parts involved in filling ensures that not a drop of
product is wasted and, even more advantageous, allows
for the automatic levelling at the end of the filling cycle,
by suctioning the excess product from the bottle back
into the tank.
Level precision
This filling method guarantees extremely precise
levels, with sigma values even lower than 0.8 (always
depending on the type of bottle being handled and the
level positioning).
Changing the level in the bottle
The level position in the bottle may be changed
without changing the tubes, within a 25 mm range
(always depending on the type of bottle being handled
and the level positioning).
The level may be changed by changing the height at
which the tank is positioned; as for all fillers that handle
glass bottles, the tank is obviously motorised.
Note that these levels for bottle filling may be
automatically corrected also based on possible
temperature differences during the day or, even more
so, between summer and winter.

17

HYDRA N-V
Filling valve for gravity level filling with slight
negative pressure.

Open-close pneumatic actuator on the air return

This control closes the air return from the bottle during
the standby stage between filler infeed and outfeed,
not involved in the filling cycle.
This device keeps large amounts of air from being
sucked in from the environment and flowing into the
tank through the tubes.
This allows us the luxury of using electric aspirators
with low air flows, hence reducing the loss of alcoholic
content that may occur during the filling cycle.
Siphoning inside the tank
One of the unique characteristics of our still water valve
is that it is siphon-free, that is to say, the body of the
valve is immersed in the annular tank.
This characteristic allows emptying the filler valves
completely and sanitising the machine during all
possible production and cleaning cycles (usually, with
level fillers, a drop of un-drainable product, of about
9.5 cubic centimetres, always remains trapped in the
siphon).

H
B
E

F
C

Tilted tank bottom

The tank bottom is tilted so as to avoid possible areas
of un-drained liquid. The supply pipes are always fitted
on a slight incline. All possible causes for product
stagnation have been eliminated (gaps due to poorly
positioned gaskets or inadequate designs). These
characteristics, as a whole, make it possible to drain
and sanitise the entire machine perfectly.
Simplicity of the filling valve
The filling valve is extremely simple and composed of
minimal parts.
A 5 mm stroke suffices to open the liquid and the air
return, so wear on parts is extremely limited.
Furthermore, there are no sliding gaskets (dynamic) that
come into contact with the filling liquid.
These features, taken as a whole, increase valve
reliability and make the valve easy to sanitise without
the need for frequent servicing.

A Slight negative
pressure
B Product tank
C Filling tube
D Pneumatic cylinder for
valve activation
E Moving bell
F Sanitisation pipe
G Pneumatic bottle lifter
H Air-vacuum return pipe

18 OCME: Filling systems in the beverages industry

HYDRA M
Flow meter filling valve

Hydra M

A
C

G
E

D
F

A Flow meter
B Product pipe
C Tap actuating
pneumatic cylinder
D Sanitisation pipe
E Plug
F Bottle support
G Rotating structure

Hydra-M
This is a rotary filler with either a mass or
magnetic flow meter. The filler may be fitted
with from a minimum of 32 to a maximum of
120 valves.
It is suited to filling bottles of any shape or
volume, either glass or PET, with extreme
volumetric precision. The production output
ranges between 8000 bph to over 100,000 bph.
This type of filler is used mainly in the
beverages sector for all types of beverages,
provided they are flat (not carbonated). If
necessary, hot filling may be carried out (8590) The filling cycle is wholly electronically
controlled and the various stages may be
programmed and are perfectly repeatable,
based on the type of product, on the type of
container, on the production speed and on
the bottling temperature. The bottle is filled
without coming into contact with the valve,
thereby averting any damage to the machine in

the unfortunate case of bottle contamination.

All machine parts that come into contact
with the filling product are made of stainless
steel Aisi 316, tilted, polished to a shine
and joined without sharp edges or gaps. All
this helps to avoid turbulence that may be
created during the filling cycle and makes it
possible to sanitise the entire machine.
The limited movement of the stem-plug
that opens the filling valves is protected by
a special membrane, to avoid sliding parts
coming into contact with the filling product.
This device reduces wear and contributes
to maximum hygiene. The false bottles used
for closed-circuit washing, sanitising and
disinfection, are completely automatic. The
tilted base completely eliminates stagnation
points and makes it easy to remove product
or detergent residues, thereby improving the
microbiological safety of the entire filling
environment. The elements described above,
along with other devices, among which the
sterile housing for the entire filling system,
allow for elevated hygiene standards, ideal
for bottling in an aseptic environment.

10

19

21
11

Features shared by all Hydra models

The base: small-sized and functional
In fillers, the base is a critical point in that, if it
is poorly designed, it may favour the persistence
and proliferation of contaminants. The base of the
Hydra machines provides considerable functional
and economic advantages. It is made of stainless
steel and it tilted to allow for easy sanitising and
avoid the creation of liquid stagnation points.
Furthermore, thanks to a careful engineering study,
it has been rationalised to reduce its complexity
and, consequently, the cost of many devices
connected to it. An additional result of its unique
design is that the space that the machine occupies
on the ground is less than that of other machines
with the same number of filling heads.
The tank
The filler tank is the chamber where the liquid is
accumulated before being transferred into the
bottles. This is a critical point for cleaning and food
safety.
The tank of the Hydra machines is annular and
made of stainless still. Instead, in Hydra M
machines the tank is central. Thanks to the shape
of the tank and the manufacturing materials,
cleaning operations are easy and effective.
Closed-circuit sanitization system
In a food liquids filler, sanitising is of fundamental
importance. For this reason, any contact between
the atmosphere and hygienic cleaning solutions
and between operators and machine parts must
be avoided, starting from the moment the cleaning
cycle is begun.

Figure 10
Closed-circuit sanitising system with
false bottles.

The Hydra N, I and I-AR versions use a closedcircuit system with semi-automatic false
bottles. The scope is to insert containers on
every filling station (this stage is manual), run
the sanitization cycle and allow the false bottles
to drain automatically so as to avoid that the
operator come into contact with the machine
and thereby potentially contaminate the
surrounding environment.
The decision to use a semi-automatic system
was dictated mostly by economic reasons,
in that the cost of this type of system is
approximately one tenth that of a wholly
automatic solution. To the contrary, as regards
the use of false bottles, in the wholly automatic
mode there are interactions that are potentially
hazardous in terms of food safety and, using the
semiautomatic solution the operator work load
is halved.
Format changeover
The plastic bottles are moved by the air
conveyors directly to the infeed starwheel that
holds the bottles by the neck.
A special (patented) device controls the pitch of
incoming bottles. No format change instruments
are required (such as side screws or infeed
starwheels) if the bottle neck size does not
change.
As for glass bottles, a patented quick-release
system is used. This system does not require the
use of tools or instruments.

Figure 11
Stainless steel annular tank.

20 OCME: Filling systems in the beverages industry

Libra R5: Electronic weight filler

his is a weight filler (weight

with load cells) that ensures
maximum precision in
measuring the product
poured into the bottle.
These machines are manufactured with
extreme care, especially for the electronic
components.
Before starting the filling cycle, the container
tare weight is calculated; subsequently, the
centrifugal force that may disturb weighing is
taken into account, as is the supplementary
weight caused by the impact of the liquid
flowing into the bottle.
Subsequent controls allow for the correction
of systemic weighing errors. This machine may
be used for any type of product, provided it is

still (non-carbonated).
Exact weight calculation is ensured by a twoor three-stage filling function (coarse and fine
fill) and guarantees excellent results even with
difficult to handle products and containers.
The machine also provides the added
advantage of clean filling, as the container
does not come into contact with the filling
valve. The weighing technology also avoids
the vertical movement of the container, hence
eliminating undesirable wear and difficulties
centring the filling valves. The quantity of
product poured into the container is easy to
parameterise in a wholly automatic manner, at
any change in the filling temperature, which
may be seasonal and in some cases even daily.

12

Figure 12
Rinser for 5 litre bottles

13

Figure 13
Double capping head for cap and
cap insert placement

21

22 OCME: Filling systems in the beverages industry

Libra R5 for spirits

lectronic weight filling for spirits and

alcoholic products represents a good
alternative to the traditional level
filling system.
Indeed, in the majority of cases in this sector, this means
glass bottle filling that, due its natural conformation, may
result in extremely variable volumes within the same
batch of bottles.
The electronic weight filling system ensures high-precision
filling, thereby providing a considerable economic advantage
in terms of the savings on volume of product at years end.
A considerable advantage provided by the Libra machines
is the possibility of mixing alcoholic products in the filler.
This system can handle more than one product on the same
machine, mixing the products directly at the filling point.
The Libra filling nozzle for alcoholic products is designed
to guarantee a perfect laminar flow; for this purpose, it is

designed to move downwards during the filling stage, as

opposed to the typical upwards movement of other weight
systems. Thanks to this feature, the Ocme valve can enter
the container during the filling stage.
Why use weight filling technology for alcoholic
products?
Accurate filling thanks to precise weight calculation
Standard deviation of about 1 g on 1 litre bottles (subject
to control)
No effect caused by temperature
Possibility of filling more products on the same machine
and mixing directly in the filler
No product loss due to the use of vacuum
No mechanical lifter for bottles means less maintenance
No contact between the nozzle and the bottle.

23

Libra R5 for 5 gallon bottles

his machine uses a weight filling

system, which is indisputably the
most precise system as compared
to other filling technologies. The
wide mouth of the 5-10 l containers is particularly
suited to high-speed filling, often achieved using
just a few filling heads. Moreover, there are the
unquestionable advantages of clean filling, as the

container does not come into contact with the

filling valve. The container does not need to be
moved vertically, hence eliminating undesirable
wear and difficulties centring the filling valves.
Furthermore, the containers, which are always
very light, do not require that the machine bear
the axial load needed to enable tap opening, as is
usually the case in traditional filling systems.

24 OCME: Filling systems in the beverages industry

Hygiene and safety for food products

very device used for the

production and packaging
of food products must meet
high safety standards. The
news media report a growing number of
cases of food adulteration and as a result
the general public is extremely sensitive to
issues regarding the quality and safety of
food products. For companies in the food
industry, investing in safety is actually more
of an opportunity than an expense, in that the
risk of compromising the corporate image,
not to mention of paying out huge sums for
damages, weighs much more than the cost
of equipping machines with avant-garde
technology systems to comply with food
hygiene and safety standards. Ocme has
invested in this field, fitting its machines with

leading-edge sanitising devices and adopting

all the construction measures required to avoid
product contamination and health hazards.
In place cleaning/sterilisation
Ocme machines are built with particular
care in the realisation of the cleaning and
sterilisation cycles to be carried out in place.
These periodic treatments are carried out
by special CIP-SIP control units, which may
be either manual or completely automatic.
The automatic units allow the operator to
automatically set the concentration and
length of the cleaning-sterilisation cycle. In
both cases, these are closed-circuit cycles to
avoid wasting acid substances that must be
disposed of accordingly.

14

Figure 14
Laminar flow system fitted with
HEPA filters to keep the filling
chamber at a slight pressure,
keeping out dust particles.

Figure on the facing page

The CIP system (Clean In Place)
guarantees maximum hygiene,
cleaning all parts that come into
contact with the product in the
filler.

25

26 OCME: Filling systems in the beverages industry

15

Figure 15
Bottle lifting system for glass
bottles

16

Figure 16
Bottle lifting system for PET
bottles

17

Rinsing
Rinsing and the treatment required to ensure
container cleanliness before it is filled. This
operation may be carried out using just water,
with sterile air, or using special sterilisation
products, depending on the results desired.
Based on the solution requested, rinsing may
be simply mechanical or, if active compounds
are used (for example, hydrogen peroxide or
ozonated water), a more thorough sanitization
may be achieved.
Positive pressure
Usually, the filling tri-block (rinser-filler-capper)
has an integral protection system, meaning
that the whole assembly is separated from the
outside environment.
Special blowers that emit sterile air (obtained
thanks to special HEPA filters) generate an
environment with a slight positive pressure;
therefore, air from the outside cannot enter the
internal machine chambers.
Tilted base
This serves to avoid water stagnation or dirt
deposits. It is easily cleaned and drainage is
collected in a single position.
Stainless steel AISI 316 L
All parts that come into contact with the filling
product are made of stainless steel and are
polish-finished and free of pores or sharp
edges. The internal surfaces that come into
contact with the product are also tilted to avoid
stagnation, so the whole machine is perfectly
drainable.

27

18

Cap treatment
Additional hygienic treatments may be
executed before applying the cap to the bottle.
The machine may be fitted with UV lamps,
ozonated water cleaning systems or dust
aspiration systems.

19

Inspection
The containers are inspected after having been
filled and capped, to analyse the contents
against the presence of impurities. If impurities
are found, the container is rejected.
Bottle lifting system (jack)
A truly efficient bottle lifting system (jack)
has been designed for the Hydra level fillers.
It works perfectly in all operating conditions,
without giving any kind of trouble.
The moving parts are so stable that wear on
the bushings and gaskets is minimal. Thanks
to system stability and sturdiness, the drive
cams can be considerably titled, permitting to
start the filling cycle at a very early stage in
the filling carrousel. It may be used for both
glass and PET containers, without requiring
great modifications. The system can work at
very high speeds (up to 100,000 bph) without
requiring external lubrication, a considerable
competitive advantage as compared to other
similar systems on the market.
The only lubrication required is for the
compressed air that generates movement,
without ever being discharged into the
environment. This means being able to
eliminate all traces of lubricant near and
around the filling valves, thereby avoiding
contamination hazards.

20

Figures 17 and 18
Some examples of rinsers in
monoblock configuration with
the filler
Figure 19
Valve detail
Figure 20
Cap feeder

28 OCME: Filling systems in the beverages industry

The ideal plant in the

beverages industry

illing, packaging, palletising and

integrated logistics.
Ocme provides turnkey solutions for
complete lines in the beverages industry, thanks to
over 50 years of experience working with the leading
international companies in this sector. The enormous
added value that Ocme offers companies in the
beverages industry is the ability to give customers the
opportunity to interface with experts specialised in
this sector who can understand, implement and advise
on strategic choices. Over the years Ocme know-how

Conveyors and logistics in beverages lines

Belt conveyors for loose containers

Conveyors for bundles, crates and cases and cartons

Ocme designs and manufactures

belt conveyors that provide the
best possible dynamic flow of
loose containers (full or empty)
between the various filling,
labelling, depalletising and
packing machines. Ocme uses
high-tech control systems to
maximise speed and accumulation synchronicity. In this way, Ocme
can ensure high performance levels with minimal downtime. All belt
conveyors are modular in design and manufactured using stainless steel
for the side frames and supports, to guarantee resistance in any food
environment.

Ocme designs and

manufactures conveyors
that provide the best
possible dynamic flow
of packages between
the various packing and
palletising machines. Ocme
uses high-tech control
systems to maximise speed and accumulation synchronicity.
In this way, Ocme can ensure high performance levels with
minimal downtime. All conveyors are modular in design and
designed and built taking into particular consideration the type
of package to be conveyed. In particular, for film-only bundles,
the conveyors are built using low-friction chains and short,
tight-pitch passages, in order to be able to create multipack
conveyor systems for small packs of film-only bundles.

29

has permitted us to perfect our engineering techniques for packaging lines and reach extremely
high levels of automation and efficiency. Ocme is capable of designing increasingly ergonomic and
compact lines, reducing the number of operators required to run the line, to a minimum. The flow
of materials (raw materials, finished product) is analysed in order to minimise warehouse stock,
constantly ensuring the best supply to the system and guaranteeing product traceability. All of this
is done without overlooking what perhaps the most important element, that is, the efficiency of the
line, or rather, the lines real warehouse output. Ocme-designed lines reach extremely high efficiency
levels also thanks to reliable, high-automation machines. Currently, we are talking about results in
excess of 90% per PET and 85% for glass-handling lines, as compared to rated output (guaranteed
performance as per DIN 8782 standards). Ocme also obtains extremely high efficiency levels on extrafast lines (for example, 55,000 bph and 78,000 bph with PET formats).

Air conveyors for empty PET bottles

Pallet conveyors

Auriga laser guided vehicles

In terms of handling
empty PET bottles,
Ocme guarantees
optimised system
integration to
ensure bottle
transfer with
minimal downtime
and damage to lighter bottles. The fans are fitted with
inverters to reduce energy consumption and excess
pressure. If the line must handle different formats, a
system for automatic body and neck guide changeover
may be inserted. In this way, the operator may choose
the various programmes to be managed directly from
the operator panel.

Ocme designs
and manufactures
pallet conveyors
for full and
empty pallets
that provide the
best possible
logistic flow of
pallets along the system. These conveyors also
comprise lifters, lowering devices, rotating tables
and shuttle systems on rails. Ocme uses high-tech
control systems to maximise speed and accumulation
synchronicity. In this way, Ocme can ensure high
performance levels with minimal downtime. All
conveyors are modular and designed and built taking
into particular consideration the type of package to
be conveyed.

Of all the
available
technologies,
laser-guided
navigation is
both the easiest
to install and
the one that
provides greatest operating flexibility. Hence, OCME
has chosen this solution to provide Auriga with a
highly reliable drive and route correction system.
Laser-guided navigation uses special reflective targets
fitted to the walls of the shuttle working area, to
provide a reference grid for shuttle orientation and
steering. In fact, this type of system does not require
the installation of any fixed or movable structures on
the plant floor.

30 OCME: Filling systems in the beverages industry

Complementary machines for the filling line

hanks to its long-standing

experience in the beverages sector,
Ocme can provide customers with
complete support for turnkey solutions. The main
machines included on the beverages line are
designed and manufactured by Ocme, providing a
further guarantee of the highest quality standards
and minimal integration difficulties.
Ocme places entire teams of specialised
engineers at the service of its customers to
develop solutions that respond to specific bottling
and handling needs. Each machine manufactured
by Ocme and any integrated device manufactured
by external suppliers are the result of accurate
studies and a rigorous selection process, with the
sole aim of guaranteeing that the performance
demanded by each customer is fully met.
Sagitta labeller
Sagitta is the line of roll-fed labellers developed
by Ocme to complete the range of beverage
bottling lines offered.
The machine can handle PET bottles with sizes
varying from 0.33 to 3 litres and has been
designed with particular attention to ergonomics,
easy maintenance and handling.
Further system flexibility is ensured by the
possibility of using a wide range of glues and
labels, in order to be able to adapt the machine to

any production requirement.

Transfer of the label from the cutter to the
transfer roller is synchronised, so that the label
does not slip on the roller itself; in this way
the OCME Sagitta machine is not dependent
on the characteristics of the label and requires
less maintenance for unit cleaning. The vacuum
system has also been greatly simplified,
guaranteeing greater component service life,
greater reliability and greater ease of use. To
accommodate the use of a variety of glue types
in order to adapt to any production environment,
the OCME Sagitta features include the possibility
of regulating the amount of glue on the label and
the temperature in each area of the system.
Full access to all machine parts is guaranteed
by the in-line positioning of labelling unit
components, the compactness of the machine and
the limited number of components fitted under
the machine base.
As a result, format change and maintenance
operations are fast and simple.
A single system with three brushless servo-drives
controls machine speed, labelling group speed
and label unwinding, guaranteeing the perfect
synchronisation of the various components.
Moreover, there is no need to phase any machine
component for format change, making this
operation faster and more repeatable.

21

Figure 21
Sagitta roll fed labeller.

31

Dorado and Antares Depalletisers

Vega shrink-wrap packers

Altair wrap-around packers

Dorado and Antares are the names that designate

OCMEs line of depalletisers. Dorado models are
low or high level depalletisers specifically designed
to handle loose containers such as jars, tin cans
and bottles with an output speed between 2 and 7
layers/minute. Layer transfer takes place by means
of a rotating pusher or a self-adjusting gripper head.
Antares models are low or high level depalletisers
specifically designed to handle secondary containers
such as plastic crates, cartons and pails with an
output speed between 4 and 15 layers/minute. Layer
transfer takes place by means of a gripping head.

Vega is the line of shrink-wrap packers specifically

designed to package bottles, flasks, jars, tins cans,
multipacks, etc. in film only, film and layer pad and
film and tray configurations, with output speeds
ranging from 20 to 450 bundles/minute.
The line of Vega shrink-wrap packers is subdivided
into 3 subgroups with different features, based on the
output capacity required.
Each category of machine may process the following
types of packages:

OCME wrap-around packers represent excellence in

global secondary carton packaging systems. Different
models are available for speeds ranging from 20 to
100 cartons per minute, handling containers such as
bottles, cans, jars, tins and
multipacks. As a complement to standard models,
versions complete with the insertion of partitions,
either traditional or pre-formed, are also available.

Perseus and Orion Palletisers

Pegasus Robot Palletiser

Manipulator layer forming system

Perseus is the line of palletisers with 90 infeed used

to handle packs such as bundles, cartons, crates
multipack, drums, etc. with output speeds of between
3 and 7 layers/minute.

Pegasus is the line of robot palletisers with multiple

gripping system or layer grippers designed to pick up
and entire layer of packs, used to handle packs such
as bundles, cartons, crates, multipacks, drums, etc.
with output speeds of up to 12 cycles/minute.

This system was designed to form layers upstream of

traditional or robotic palletisers. Three functions have
been integrated into one system:

Orion is the line of palletisers with in-line infeed used

to handle packs such as bundles, cartons, crates,
multipacks, pails, etc., with output speeds ranging
between 5 and 9 layers/minute.

film only bundles

film + layer pad bundles
film+ tray bundles
film+ U-board bundles

Package turning
Layer forming
Layer compacting

32 OCME: Filling systems in the beverages industry

33

The marketing value of filling machines

s it constitutes the heart of a filling line, the filler can greatly impact upon a
companys production and commercial output and potential. For companies in the
beverages sector, the marketing division, as the lead player and primary driver for
innovation, requires that the entire production division meet flexibility requirements
geared at giving the company a competitive edge vis--vis, first and foremost, distribution and,
secondly, the end consumer.
The beverages sector is affected by various trends, some of which are the result of changes
in consumer purchasing habits, while others are associated to distribution requirements. For
example, the trend towards increasingly lighter packages (both bottles and secondary packaging) is
appreciated by many consumers and distributors; for their part, companies in the beverages industry
can leverage the fact that new-generation machines and lines are capable of handling fragile and
unstable containers with greater ease, to emphasise corporate awareness regarding environmental
and energy saving issues. Moreover, let us not forget that container shape is also an important
element of differentiation: the fewer the limits imposed on designer creativity (especially those
deriving from technical obstacles pertaining to production lines), the greater the opportunities to be
seized from a commercial point of view.
And that is not all. Safety, be it food safety or plant operator safety, is an increasingly topical issue.
Here again, the marketing division of a beverages company may sell the safety level of its systems
as an ethical advantage of its work policy.
Substantially, the role of production technology should be viewed not only in terms of a technical
platform, but also as a vehicle to transmit values, through the values chain, right to the end
consumer. The extent to which this may be possible depends on the extent to which the production
technology guarantees high standards in terms of efficiency and repeatability.

34 OCME: Filling systems in the beverages industry

Environmental respect

owadays, protecting and

caring for the environment,
for persons and for everything
that surrounds us are
fundamental aspects of corporate choices.
Companies cannot afford to ignore issues such
as environmental impact and industrial safety,
neither in the organisation of production, nor in
terms of products.
For this reason, OCME tri-block filling systems
and all other integrated systems and equipment
for complete beverages lines meet the growing
demand for reduced environmental impact and
energy savings.
On this matter, one of the most important
features of new-generation fillers and
palletisers is the capacity to handle lighter
containers with greater ease, reducing impact
stress and friction. Less packing material
means an immediate saving on raw materials
and, on the whole, less waste to be disposed of
for the general community.
The use of every process fluid, from rinsing
solutions to the use of ozone to treat containers
and capsules, is optimised to reduce or
eliminate discharge outside production sites
and guarantee rational, waste-free use.
Furthermore, new shrink-wrapper ovens are
designed to guarantee more than 20% energy

savings as compared to older ovens. One

new-generation Vega shrink-wrapper alone
guarantees savings of up to 30,000 Euro of
motive power per year and over 75 tons of CO2
emissions (generally required to produce energy
savings).
Altair wrap-around packers are designed to use
the least possible amount of glue while still
guaranteeing sturdy, logistics-proof packs;
this means less energy required to keep the glue
at the right temperature and less material used
on every carton.
OCME has been committed for several years to
the OCME WorldCare project, a corporate plan
aimed at education and proactive intervention
in environmental protection issues, through
segregated waste collection and the careful
use of energy and raw materials in general. The
principles of the project focus on raising the
awareness of design engineers around issues
such as environmental protection and dwindling
resources. The aim is to make new series of
machines and systems with performance levels
that can be made to grow hand in hand with the
capacity to guarantee ecologically sustainable
development.

Corporate environmental respect programme

All rights reserved. All registered trademarks mentioned herein belong to their rightful owners.
OCME declines any and all responsibility for the contents of this document insofar as technical data, characteristics and descriptions may vary without advance notice.
OCME is not in any way liable for damages deriving from omissions or inaccurate information contained in this document.

35

All the OCME technologies dedicated

to your sector

One of the characteristics for which OCME is renowned for in the

market is the companys flexible approach to customer needs.
We believe that each sector must be followed with specific care,
because each has specific needs. For this reason, our staff of
professionals is specialised in responding to the needs of every
single customer, based on the unique characteristics of each
sector.

Beer
Mineral water
Soft-drinks
Wines and spirits
Food
Edible oils
Tissue
Petrochemicals
Pharmaceuticals
Products for personal and home care

OCME UK Ltd.
King John House, Kingsclere Park
Kingsclere - Newbury
Berkshire RG20 4SW (UK)
Phone: +44-1635-298171
Fax : +44-1635-297936
e-mail: sales@ocme.co.uk
OCME AMERICA CORPORATION
5300 N.W. 33rd Avenue, Suite 105
Ft. Lauderdale, FL 33309
Phone: 954-318-7446
Fax: 954-634-0238
e-mail: info@ocmeusa.com

The aim of this publication is to present our experience and our

technologies, as applied to complete lines for the beverages sector.
As for all OCME products, the systems and equipment devices
and the services provided by our Company for the duration of the
systems service life, are designed to work at high production
output, providing customers with sound support in the strategies
choices to be implemented.
Today, companies in the beverages sector have an incredible
opportunity to differentiate and increase their competitive edge,
aiming at efficiency and the integrated automation of the production
plant, from filling right to handling pallets by means of laser guided
vehicles; all of this, thanks to OCME technology.

OCME FRANCE
42 avenue Montaigne
75008 Paris
Phone:+33 (0) 6 27.89.36.20
email: commercial@ocme.fr
OCME Packaging Equipment (Jiaxing)
No.289 Mu Yang Road,
Jiaxing Economic Development Zone,
314033 Jiaxing City,
Zhejiang Province, P.R.China
Phone: +86-573-83971680
Fax: +86-573-83971690
E-mail: info@ocme.cn
OCMEXICO Embalaje, S. de R.L. de C.V.
Homero 425 Desp. 2, Torre B
Col.Chapultepec Morales
Mxico D.F., CP 11570
Phone: +52-55 52542401 ext. 103
Fax: +52-55 52542401 ext. 106
e-mail: info@ocme.com.mx

www.ocme.com

Tutti i diritti sono riservati. All rights reserved.

OCME S.r.l.
Via del Popolo, 20/A
43122 Parma (Italy)
Phone +39-0521-275111
Fax +39-0521-272924
e-mail: info@ocme.it

Our task, as suppliers of packaging, filling and logistics

technologies, is not just to install a system, simply providing a
solution for an immediate problem. Rather, we believe that our job
is to supply a vision of the future of production in the packaging
and to produce solutions that are ahead of their time. At least, this
is what we have been doing since 1954.

GraphoServiceParma

OCME and filling systems in the beverages industry

CL-BEV-EN Rev. 1.0-0907

MOVING IDEAS