BLE - Foam Control

What is the Cavitus BLE-Foam Control solution?

Cavitus has perfected ultrasound technology for use in the food and beverage industry, in particular addressing the foam issues present in the majority of beverage filling lines. The highly efficient titanium ultrasonic bubble breaker provides an easy to install, safe and cost-effective method of removing foam, in an increasingly competitive market.

The Cavitus BLE-Foam Control solution can increase your productivity by 10%, deliver another $125,000 to your bottom line and provide a ROI in less than one year.

 

Transducer/Sonotrode Specifications

Line suitability

Canning lines

Bottling lines

Filling lines with units up to 70 mm openings

Line speeds up to 120,000 units/hr

Cold fill (non aseptic) beer lines

Carbonated soft drink lines

Cold fill (non aseptic) juice lines

Cold fill (non aseptic) dairy lines

Ingress Protection class

IP67

Sonotrode frequency

20 kHz

Sonotrode amplitude

120 µm (peak to peak)

Construction material

ALTEF (Teflon/Aluminium ceramic interface)

Stainless steel (AISI 316, A4)

Titanium Alloy Ti-6Al-4V

Silicon HF and signal cables

Permissible ambient operating conditions

Temperature (10o- 40o Celsius) continuous

SIP/CIP conditions (100 o Celsius for 20 minutes max.)

Reference specific SIP/CIP conditions and material resistance prior to installation

Control Cabinet Specifications

Power requirement

Single phase

180-260 V

50-60 Hz (cos φ > 0.95)

15 A

2.5 mm2

150 W (peak)

75 W (continuous)

Ingress Protection class

IP66 (without cooling fan)

Automated control

Input signals

Line speed (via 0-10 V, or 4-20 mA analogue)

Ultrasound start (24 V DC impulse signal)

Ultrasound stop (24 V DC impulse signal)

24 V DC for relay output signals

Automated control

Output signals

Ultrasound running (24 V DC continuous signal)

Ultrasound alarm (24 V DC continuous signal)

Cooling option

Cabinet extraction fan

Construction material

Brushed stainless steel (EN 1.4301, AISI 304, A2)

Permissible ambient operating conditions

Humidity (20%-80% (non-condensing)

Temperature (10o- 40o Celsius)

Control Logic System Options

Control logic systems

Option 1 - Relay control logic

Option 2 - PLC control logic

Component packages available

Siemens

Allan Bradley

Siemens

Allan Bradley

Control interface

Manual push buttons

4” touch panel

Automated control capability

Continuous internal frequency management (20 kHz)

Continuous internal power management (max 1.2 kW)

Highly regulated continuous internal frequency management (20 kHz)

Highly regulated continuous internal power management (max 150 W)

Safety features

System shutdown with power overload

System shutdown with frequency shift

System shutdown with manual ‘emergency’ power cut button

Performance level D/SIL2 dual channel emergency stop interlock

System shutdown with filling line enclosure opening

System fault with transducer temperature breach

System fault with control cabinet temperature breach

System shutdown with power overload

System shutdown with frequency shift

System shutdown with manual ‘emergency’ power cut button

Performance level D/SIL2 dual channel emergency stop interlock

System shutdown with filling line enclosure opening

System fault with transducer temperature breach

System fault with control cabinet temperature breach

System shutdown with cabinet door opening

Additional features

 

Continuous fault logging for root cause analysis

Remote diagnostics capability

Define linear functions for output amplitude vs line speed variability via the touch panel

Manual amplitude override feature during automation mode

Security login codes for various levels of access

 

Download PDF Data Sheet

What problems does it solve?

The operating principle of the foam control system is that it breaks foam that is in the head space, or above the neck of the can and bottle. It uses state of the art technology in high powered ultrasonics to resonate the air between the sonotrode and the foaming product. This resonance collapses the foam, allowing it to be returned into the can or bottle.

With the application of the Cavitus system, product losses due to over foaming are reduced, sometimes eliminated. These savings can make a significant impact on the plant revenue. With product losses reduced, filler volume set points (electronic for volumetric, longer vent tubes for mechanical fillers) can be reduced. Reducing setpoints further reduces product losses due to the increase in head space volume.

Bottling and canning lines are often run at slow speeds to reduce the degree of foam creation during filling, and across the transition area before capping and seaming. A key indicator of this problem is if a production line is running at less than its original design capacity (OEM rating). By eliminating the excess foam created in the filling process using ultrasound, Cavitus can deliver an increased line speed/production of 10% or more.

Foam generation increases with product temperature due to the shift in carbonation saturation levels. Many plants reduce filling temperatures close to zero Celsius in order to minimise foaming. With the application of the Foam Control system significant savings in chilling and rewarming utilities can be made which further reduce the plants carbon footprint.

Foam Control for the beer industry

Application of the foam control unit on beer lines can yeild multiple benefits. The benefits are line specific. The following outlines some benefits that may be achieved

  • Reduction in carbon dioxide consumption on the line
  • Increase in production rates due to foam restricted line speed
  • Reduction in beer losses from over foaming
  • Reduction in contamination risk from bubble breakers and during seaming
  • Increases to filling temeprature when limited my foaming
  • Improve the efficiency of hot water jetters

Foam Control for the beverage industry

Application of the foam control unit on beverage lines can yeild multiple benefits. The benefits are line specific. The following outlines some benefits that may be achieved

  • Increase in production rates due to foam restricted line speed
  • Increase can/bottle yield
  • Improve the efficiency of nitrogen dosers
  • Reduce your waste and rejects rates
  • Reduce the risk of cap, thread and seal contamination
  • Increases to filling temeprature when limited my foaming

How easy is it to install?

The unit is capable of being deployed on even the highest speed filling lines and the de-foaming head footprint, either single or double, is small.
It only takes around an hour to install this add on, robust, retro-fit technology and many major bottling plants worldwide have already successfully integrated the system into their production lines.

How does it work?

Want to know more?

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