According to the needs of the improvement and development of the domestic liquid packaging machinery manufacturing level, the flushing, filling and capping machine (“three-in-one” type) for plastic anti-theft bottle cap sealing and threaded bottle mouth polyester bottle filling without gas liquid is used in beverages. The manufacturing industry has a wide range of applications. In order to regulate product quality, optimize technical parameters, and enhance applicability, this standard is specially formulated.
In order to clarify the high-density polyethylene (HDPE) plastic anti-theft caps that this equipment is suitable for when filling materials at room temperature with heat sterilization or hot filling, this standard puts forward specific technical requirements in Appendix A.
Appendix A of this standard is an appendix to the standard.
This standard is proposed by the Industry Management Department of the State Light Industry Administration.
This standard is under the jurisdiction of the National Standardization Technical Committee of Alcohol and Beverage Machinery
01.
Scope
This standard specifies the definitions, abbreviations, requirements, test methods, inspection rules, markings, packaging, and shaft storage for still beverage rinsers, fillings, and capping machines.
This standard is applicable to the rinsing, filling and capping machines (hereinafter referred to as “products,”) for filling and filling non-carbon dioxide beverages in threaded polyester (PET, PEN/PET) bottles with plastic anti-theft caps.
This standard is also applicable to other low-viscosity, low-foam, non-explosive, non-gas-free liquid products filled with threaded bottle-top polyester bottles sealed with plastic anti-theft caps.
02.
Normative references
The following standards contain provisions which, through reference in this standard, constitute provisions of this standard.
At the time of publication, the editions indicated were valid. All standards are subject to revision and parties using this standard should explore the possibility of using the latest edition of the following standards.
GB/T 3768-1996 Acoustics – Determination of sound power level of noise sources by sound pressure method – Simple method using envelope measurement surface above reflecting surface
GB 9687-1988 Hygienic standard for polyethylene moldings for food packaging
GB 9691-1988 Hygienic standard for polyethylene resin for food packaging
GB 9969.1-1998 User Manual for Industrial Products General Provisions
GB/T 13306-1991 Signs
GB/T 13384-1992 General technical conditions for packaging of mechanical and electrical products
GB/T 14253-1993 General technical conditions for light industrial machinery
GB 14944-1994 Hygienic standard for polyethylene bottle cap gaskets and pellets for food packaging
GB 16798-1997 Food Machinery Safety and Hygiene
GB/T 17876-1999 Packaging container plastic anti-theft bottle cap
QB 1868-1993 Polyester (PET) soft drink bottle
03.
Terms and Definitions
This standard uses the following definitions and abbreviations.
3.1 Definitions
3.1.1 Screw cap: capping machine screw the plastic anti-theft bottle cap on the threaded bottle mouth of the container.
3.1.2 Opening torque: the torque required to unscrew the plastic anti-theft bottle cap that has been sealed in the container mouth.
3.1.3 Heat-setting PET bottle: a heat-resistant PET bottle made by increasing the temperature of the blow mold and prolonging the holding time to increase the crystallinity of the PET.
3.2 Abbreviations
3.2.1 PET: Abbreviation for polyethylene phthalate.
3.2.2 PEN: Abbreviation for polyethylene glycol zeolate.
3.2.3 PEN/PET: Copolymer of PEN and PET
04.
Requirement
4.1 The product shall comply with the provisions of this standard and be manufactured in accordance with the drawings and technical documents approved by the prescribed procedures.
4.2 Working conditions
4.2.1 Polyester bottles should comply with the regulations of QB 1868. The materials should be filled at room temperature. If heat sterilization or hot filling is required, PEN/PET bottles should be used. Heat-set PET bottles that have not been stored for long periods of time or have not been exposed to moisture can also be hot-filled. Recycled bottles must not be used.
4.2.2 Plastic anti-theft bottle caps should meet the requirements of GB/T 17876. When the material is filled with hot sterilization or hot filling at room temperature, the plastic anti-theft bottle caps should also meet the requirements of Appendix A.
4.2.3 Filling material temperature: normal temperature filling or hot filling not higher than 95°C.
4.2.4 The pressure of water supply (liquid) for rinsing and filling: not less than 0.2 MPa, and the pressure fluctuation value is less than 0.03 MPa,
4.2.5 Compressed air pressure: 0.6 MPa-0.7 MPa,
4.2.6 Power supply: The rated voltage of the power supply of the product is 380 V, the voltage fluctuation value should not exceed the rated value of ±10%, and the frequency is 50 H: or 60 Hz.
4.3 Basic requirements
4.3.1 The product should be able to properly adjust or replace the bottle-delivery-related parts within a certain range to meet the requirements of the user’s container dimensions.
4.3.2 The quality of welded parts, machined parts and assembly of products shall comply with the provisions of GB/T 14253.
4.3.3 The product should run smoothly, without abnormal sound, and the bottle feeding system should not be stuck.
4.3.4 Water and gas pipelines and valves should be sealed and reliable without leakage.
Instrumentation and control components should be sensitive and consistent with working procedures.
4.3.5 The product shall have the function of no bottle filling at the filling station and no capping function when there is no bottle at the capping station. 4.3.6 The material selection, sealing, electrical system, protection and other safety and health performance of the product shall comply with the provisions of GB 16798.
4.4 Use performance
4.4.1 The production capacity should reach the nominal production capacity.
4.4.2 The flush rate should reach 100%
4.4.3 Qualified rate of filling accuracy
The product adopts the filling principle of controlling the liquid level, the filling liquid level accuracy is ±3 mm, and the filling accuracy qualification rate is not less than 98%; the net content of the lowest liquid level in the filling accuracy qualified product is less than 98.50 of the nominal net content, and The average net content must not be lower than the net content stated on the label.
4.4.4 After screwing the cap and sealing, it is tight and leak-free, and the cap is not skewed or scratched, and the sealing pass rate is not less than 9900.
4.4.5 Opening torque of bottle cap. 6N”m-2.2N”m, the opening torque fluctuation value of the same batch of bottle caps is not more than ±20%.
4.4.6 The bottle damage rate is not more than 0.1%
4.4.7 Cover loss rate not more than 0.8%
4.4.8 Product reliability index
Under the principle of complying with installation technical requirements and normal use:
a) The first overhaul period shall not be less than 4 000 h;
b) The service life of the product is not less than 12 000 h,
4.5 Noise Index
When the product is running without load, the noise (sound pressure level) is not greater than 80 dB(A)
4.6 Energy consumption index
According to the nominal production capacity, the power consumption of the product (excluding the water supply pump) is not more than 1.2 kW·h/t filling material.
05.
Test methods
5.1 Test conditions
5.1.1 The test site should be spacious, and the product placement should meet the installation technical requirements in the product manual.
5.1.2 The working conditions of the test shall meet the requirements of 4.2.
5.2 Use performance test
5.2.1 Determination of production capacity
The product was filled with water as the medium in the manufacturing plant for the filling test.
The product is filled with the filling material as the medium for the filling test at the production site.
The filling level accuracy should be adjusted and the capacity should meet the requirements. In the case of continuous and normal operation of the product, the test time is not less than 20 minutes, and the measured production capacity should reach the nominal production capacity after conversion.
5.2.2 Determination of flush rate
20 containers soaked with 3% sodium hydroxide solution will be sent to the product’s rinsing device when the product is in normal operation. After the container is rinsed, at the outlet of the rinsing device, use the pH test paper method to test the residual water on the inner surface of the bottle. Its pH should be consistent with the rinse water (pH6. .2 requirements.
5.2.3 Determination of the qualified rate of filling accuracy
When the product is in normal operation, 200 bottles of filled finished bottles are randomly and continuously intercepted within 20 minutes. After the cap is opened, use a steel ruler with a division value of 1 mm to measure and record the distance from the bottle mouth to the liquid surface, and calculate the arithmetic average.
The sample bottle whose difference between the distance from the bottle mouth to the liquid level and the average value does not exceed the filling level accuracy is qualified for the filling level accuracy.
Randomly and continuously select 10 bottles from the sample bottles with qualified filling level accuracy, and use the sample bottle with the minimum division value of 5 mL to measure the net content of the lowest liquid level sample bottle and the average net content of the 10 bottle sample bottles, which should meet the filling level. Loading capacity accuracy requirements.
Count the number of qualified bottles b, and calculate the qualified rate of filling accuracy according to formula (1), which should meet the requirements of 4.4.3
F=b1/200 x 100 （1）
where:
F Qualified rate of slip fitting accuracy, %;
b1 – Filling accuracy qualified sample bottles, bottles.
5.2.4 Determination of sealing qualification rate
When the product is in normal operation, 200 bottles of filling finished bottles are randomly and continuously intercepted within 20 minutes. First, the appearance of the sealing quality is visually inspected, and the unqualified bottles with skewed and scratched plastic anti-theft bottle caps are eliminated.
The polyester bottle was inverted for 1 min without leakage, and after applying 400 N pressure on both sides of the bottle body, the bottle that remained without leakage for 10 s was qualified.
Count the number of qualified bottles b, and calculate the qualified rate of sealing according to formula (2), which should meet the requirements of 4.4.4.
S=b2/200 x 100 （2）
where:
S—sealing pass rate, %;
b2—Number of qualified sample bottles for sealing, bottles.
5.2.5 Determination of opening torque
When the product is in normal operation, randomly select 10 bottles to fill finished bottles, and use a digital torque meter with a dynamic accuracy of 1% to measure the opening torque of the plastic bottle cap and the container, which should all meet the requirements of 4.4.5. 5.2.6 Determination of bottle damage rate
When the product is in the production capacity test, record the total number of bottles of the input product and the number of bottle losses b in the processes of rinsing, filling, and capping within 20 minutes (the damage due to the poor quality of the container itself is not counted), press Formula (3) calculates the bottle damage rate, which should meet the requirements of 4.4.6.
Lb=b3/B x 100 （3）
where:
Lb bottle loss rate, %; b, — bottle loss, bottle;
B—The total number of bottles of the product infused within 20 minutes, bottles.
5.2.7 Determination of cover loss rate
When the product is in the production capacity test, record the number of bottle caps input into the product within 20 minutes and the number of bottle caps damaged during the screwing and sealing process (the damage due to the poor quality of the bottle cap itself is not counted), according to formula (4). ) to calculate the cover loss rate, which shall meet the requirements of 4.4.7.
Lc=c1/C x 100 （4）
where:
Lc : Cap loss rate, %;
c1: The number of bottle caps damaged, only;
C—The total number of caps of the input product within 20 minutes, only.
5.3 Performance test of the whole machine
53.1 Visual inspection
Visual inspection of the appearance quality of the product shall meet the requirements of 4.3.2.
5.3.2 Electrical safety performance test
Before the product idling test, it should be carried out according to the provisions of 5.8 in GB16798-1997.
5.3.3 Dry running test
The product is gradually adjusted from low speed to high speed, continuously runs for 1h under the condition of nominal production capacity, and conducts an idling test, which shall meet the requirements of 4.3.3.
5.3.4 Noise test
In the process of product idling test, according to the provisions of GB/T3768, the sound level meter is used to measure the working noise of the product, which should meet the requirements of 4.5. The measuring surface is a rectangular plane hexahedron-shaped surface whose sides correspond to the plane of the reference body, and the measuring distance is 1M.
The position of the microphone is shown in Figure CS in Appendix C of GB/T3768-1996, but the top surface of the product is not tested.
5.3.5 Filling test
After the product has passed the empty running test, the filling test shall be carried out with water or filling material as the medium, and the test time shall not be less than 20 minutes, which shall meet the requirements of 4.3.4 and 4.3.5.
5.3.6 Measurement of power consumption
At the same time as the production capacity determination is carried out.
When the product is in the condition of the nominal production capacity, use the electricity meter to measure the power consumption value of the product within 20min. Count the quantity B of the filling finished product, and calculate the power consumption according to the formula (5), which should meet the requirements of 4.6.
P=1000W/BVp （5）
where:
P—power consumption, kw h/t;
W—power consumption value, kw h;
B—the number of finished products filled, bottles;
V—the rated filling volume of the container, L/bottle;
p—filling material density, kg/L
06.
Inspection Rules
6.1 Inspection classification
Product inspection is divided into factory inspection and type inspection.
6.2 Factory inspection
6.2.1 The factory inspection items shall be inspected according to the requirements of 4, 3.2-4.3.6, 4.4.1-4.4.4.
6.2.2 Judgment rules Products must be inspected by the quality inspection department of the manufacturer one by one, and the products can be shipped out after passing the inspection and issuing a certificate of conformity. If there are any unqualified items in the factory inspection, re-inspection is allowed.
6.3 Type inspection
6.3.1 In one of the following situations, type inspection shall be carried out
a) When the product is put into production and identified;
b) After the product is officially produced, if there are major changes in the structure, material and process, which may affect the performance of the product;
c) When the product has been suspended for more than two years and resumed production;
d) When there is a big difference between the factory inspection results and the last type inspection;
e) When the national quality and technical supervision agency proposes a type inspection requirement.
Type inspection can be carried out at the user’s production site.
63.2 Type inspection items
Type inspection shall be carried out item by item according to all the requirements specified in this standard (except 4.4.8).
6.3.3 Sampling
Simple random sampling as follows:
a) The annual output is less than 20 units, sample 1 unit from any batch;
b) The annual output is greater than 2. Sets, 2 sets of sleeve samples from any batch.
6.3.4 Judgment Rules
If all items of type inspection are qualified, the product is qualified. If there is any unqualified item, it should be re-examined, and if it is still unqualified, it will be judged that the product type inspection is unqualified. However, when 5.3.2 electrical safety performance test and 5.3.4 noise test fail, the product is judged to be unqualified. Re-inspection is not allowed
07.
Marking, packaging, transportation, storage
7.1 Logo
The product should be fixed with a sign in an obvious position, and the sign should comply with the provisions of GB/T 13306. Signage includes:
a) Product name, model specification;
b) Main technical parameters of the product;
c) Dimensions,
d) quality;
e) the name of the manufacturer;
f) Date of manufacture and serial number.
7.2 Packaging
Product packaging should comply with the provisions of GB/T 13384.
When the product leaves the factory, the following technical documents should be attached:
a) The product qualification certificate must indicate the adopted standard number;
b) Instructions for use of the product, the preparation of which shall comply with the provisions of GB 9969.1;
c) packing list;
d) Random spare parts list.
7.3 Transport
The overall packaging and transportation of the product or the packaging and transportation of the parts shall meet the requirements of land and water loading and transportation. When loading and unloading, it should be stable to prevent violent collision.
7.4 Storage
The product should be stored in a ventilated, dry, rain-proof and non-corrosive gas indoor venue, and it is not allowed to store in the open air. When the product has a storage period of more than 6 months, when it leaves the factory or is used, it should be checked after unpacking, and the parts that may affect the performance of the product should be dealt with.
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