Filling Monoblock

Filling Monoblock

A filling monoblock is an integrated machine combining multiple bottling functions into a single unit, typically filling and capping operations. When a third function is added, such as rinsing, the configuration is called a filling triblock. This integration represents essential equipment in bottling lines, processing bottles through rinser, filler, and capper in immediate sequence.

Position in the Bottling Line

The filling monoblock is positioned at the beginning of the bottling line:

• Glass bottle lines — immediately after the depalletizer
• PET bottle lines — after the blow molding machine

How Filling Monoblocks Work

The operation begins as bottles arrive in single file via a conveyor belt sized to the bottle format. The process sequence includes:

1. Infeed auger (worm) — positions bottles at equal distances
2. Star wheel alignment — transfers bottles to processing stations
3. Rinsing (if equipped) — clamp grips bottle neck, inverts it; nozzle injects peracetic acid, water, or disinfectant; filtered compressed air dries the interior
4. Filling — product flows through valves into containers
5. Capping — closure applied immediately after filling
6. Discharge — bottles exit to downstream equipment (capsuling machine, wirehooder)

Filling Requirements

Throughout the filling phase, the machine must avoid four critical issues:

• Product contamination — no foreign substances
• Product oxidation — minimal air contact
• Quantity alteration — precise volume control
• Quality alteration — preserving organoleptic properties

The time between filling and capping must be as short as possible — measured in seconds — during which nothing should contact the product. All components must comply with health and hygiene regulations for food contact.

Monoblock Configurations

Gripping Systems

Filling monoblocks use two main bottle gripping methods:

Latest generation monoblocks predominantly use neck grip systems, particularly for PET applications where bottle deformation must be avoided. The 304 steel equipment accommodates different bottle formats through changeover parts.

Turret Configurations

Filling monoblocks may include two, three, or four turrets depending on the application:

• Two turrets — filler + capper (basic monoblock)
• Three turrets — rinser + filler + capper (triblock)
• Four turrets — additional functions or dual capping systems

Multiple capping turrets can be mounted on the same machine table with different closure systems, including rotating turrets with two cap types on the same bearing axes.

Filling Monoblock Types

Isobaric Filling Monoblock

The isobaric filling monoblock equalizes pressure between the liquid tank and container, essential for carbonated products. The process pressurizes containers with gas (typically CO2) before filling.

Key components:

• Pressurized storage tank
• Isobaric filling valves — precise liquid flow regulation
• Pressurization system — pre-pressurizes containers
• Rotary table — moves containers through filling and closing stations

Advantages of isobaric systems:

• Fills carbonated drinks without effervescence loss
• Reduced foaming during filling
• Maintains final product quality

Considerations:

• Higher construction and maintenance complexity
• Requires continuous pressure monitoring
• More complex operation than gravity systems

Ideal for: beer, carbonated soft drinks, sparkling wines, sparkling water

Gravity Filling Monoblock

Gravity monoblocks offer simpler construction and operation, suitable for non-carbonated liquids. Product flows by gravitational force without pressurization requirements.

Ideal for: still wine, water, spirits, liqueurs

Filling Monoblock for Edible Oil

The triblock for edible oil typically features three turrets: blowing, filling, and capping. Filling systems include:

• High vacuum chamber filling
• Volumetric filling

Characteristics:

• Processes PET bottles, glass bottles, and cans
• Multiple cap formats with appropriate changeover parts
• Universal star system available for different formats on rotary machines
• Excellent speeds achievable with proper maintenance

PET Filling Monoblocks

Monoblocks for PET have evolved from bottom-grip systems (allowing dual glass/PET use) to modern neck-grip configurations. Current designs prevent bottle crushing during filling and capping phases.

PET monoblocks can be configured for both isobaric (carbonated) and flat liquid (still) products, with equipment in 304 stainless steel supporting multiple bottle formats.

Capping Section

The capping system mechanically applies closures immediately after filling. Operation sequence:

1. Hopper — orders caps in correct orientation
2. Cap pickup — capper retrieves positioned caps
3. Application — bottle on plate beneath compression tool; cap inserted or screwed depending on closure type

After capping, bottles proceed to the capsuling machine or wirehooder (for sparkling wines).

Mechanical vs. Electronic Filling Machines

When purchasing individual filling machines rather than complete monoblocks:

For both types, verify that the manufacturer remains active for technical and electro-mechanical assistance.

Purchasing Used Filling Monoblocks

Used filling monoblocks offer savings of 35% to 60% compared to new equipment. Key evaluation factors:

• Working hours — indicator of remaining service life
• Maintenance history — regular service by specialized technicians
• Overhaul status — mechanical and aesthetic condition
• Production requirements — matching capacity to actual needs
• Product compatibility — appropriate filling technology (isobaric, gravity, volumetric)
• Container types — glass, PET, can compatibility