Aseptic Bag Filling Machine

Short Description:

The Aseptic Bag Filling Machine by EasyReal Tech is designed to fill sterile liquid food products—such as natural fruit juices, pulps, purees, or concentrates—into 200L or 220L aseptic bags housed within drums/1~1400L within bulk boxs. This advanced system ensures long-term preservation: natural products maintain freshness for over one year at ambient temperatures, while concentrated variants (e.g., juices, pastes, or purees) remain stable for more than two years.

Ideal for high-quality liquid food production, EasyReal’s machine handles demanding applications, including tomato paste, fruit jams, creams, and similarly viscous materials. Engineered for precision and reliability, it guarantees sterility and product integrity throughout the filling process.

Developed by EasyReal Tech’s expert engineering team, the machine leverages decades of specialized experience in fruit and vegetable processing technology. This expertise ensures cutting-edge performance, meeting stringent industry standards for aseptic packaging and food safety.

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Description

Aseptic Bag Filling Machine: Precision & Reliability for Sterile Liquid Packaging

The Aseptic Bag Filling Machine by EasyReal is engineered to fill sterile liquid food products (e.g., fruit juices, tomato paste, purees, jams, cream) into 200L or 220L aseptic bags within drums/1~1400L within bulk boxs. Designed for high-quality demands, this robust machine ensures product integrity and extended shelf life, making it ideal for sensitive liquid food materials requiring stringent hygiene standards.

Key Benefits:

Extended Preservation: Integrates seamlessly with UHT sterilizers to form a complete aseptic filling line. Post-processing, natural juices/purees retain freshness for 12+ months at ambient temperatures, while concentrated products (e.g., pastes) last 24+ months.
Precision & Versatility: Handles diverse viscosities and product types with ±0.5% filling accuracy.
User-Friendly Operation: Simplified touchscreen controls streamline bag selection, sterilization, filling, and sealing.

Core Components:

Aseptic filling head
Precision control system
Steam sterilization unit
Pneumatic tray (1–25L bags)
Customizable conveyors (roller/belt)
Durable stainless-steel frame

How It Works:

Select Bag Type: Choose parameters via intuitive touchscreen.
Sterilize & Prep: Automated steam injection ensures a sterile environment.
Fill & Seal: Precise volumetric filling and hermetic sealing in a contamination-free chamber.
Output: Finished bags are conveyed for storage or transport.

Applications:
Ideal for semi-finished liquid products destined for food factories or export, including:

Tomato paste & vegetable concentrates
Fruit pulps, purees, and dairy products
High-acid or viscous liquids (e.g., jams, syrups)

Why EasyReal?
Our Aseptic Bag Filling Machine combines cutting-edge automation with industrial durability, reducing downtime and ensuring compliance with global food safety standards. Trusted by manufacturers worldwide, it’s the go-to solution for sterile, large-volume packaging.

What kinds of Aseptic bag filling systems could be supplied?

Expert Engineering, Tailored Solutions for Every Production Need

At EasyReal TECH, our experienced engineering team specializes in designing adaptable aseptic packaging systems to meet diverse industrial demands. Whether your facility requires high-speed automation or compact configurations, we deliver precision-engineered solutions that align with your unique production environment.

Customizable Aseptic Filling Systems:

Bag-in-Box & Bag-in-Bin Machines: Ideal for flexible packaging of sterile liquids in varied container formats.
Aseptic Bag in Drum Filling Systems: Configured to your exact specifications, including:
- Single/Double/Multi-Head Fillers: Scale throughput efficiently with modular designs.
- Compact to High-Capacity Models: Choose from Single-Drum Fillers or space-efficient 4-Drum Tray Systems for bulk operations.

Why Partner with EasyReal?

Precision Adaptability: Modify machine parameters (speed, volume, sterilization protocols) to match your product’s viscosity and sterility requirements.
Future-Ready Design: Upgrade or expand systems seamlessly as production needs evolve.
Global Complian

Feature

1.Robust Construction
Premium SUS304 stainless steel main structure ensures corrosion resistance and compliance with food-grade hygiene standards.
2.European Engineering Excellence
Combines Italian processing technology with German automation systems, fully compliant with Euro Standard EN 1672-2.
3.Multi-Scale Compatibility
Spout sizes: 1"/2" (25mm/50mm) standard options
Bag capacity: 200L-220L standard models (Customizable from 1L to 1400L)
4.Smart Control System
Independent Siemens S7-1200 PLC with HMI touchscreen enables precise parameter control and real-time monitoring.
5.Sterilization Assurance
Full SIP/CIP integration (pH-resistant surfaces)
Steam barrier protection for filler head (120°C sustained)
Triple-sealed moving components
6.Dual Precision Measurement
Option for:
✓ Coriolis mass flowmeter (±0.3% accuracy)
✓ Dynamic weighing system (±5g resolution)
7.Maintenance-Optimized Design
Tool-free quick-change parts
<30 min CIP cycle time
Universal connector interfaces
8.Global Component Strategy
Critical systems feature:
• Festo/Burkert pneumatics
• SICK sensors
• Nord gearmotors
• IFM monitoring modules
9.Energy Efficiency
≤0.15kW·h/L power consumption with heat recovery system
10.Certification Ready
Pre-configured for CE/PED/3-A certification documentation

More Details of Compact Aseptic Filler

Application

1. Juice & Concentrates
Full-spectrum processing for NFC juices (Not From Concentrate) and 65°Brix+ concentrates.

2. Puree Solutions
Homogenized fruit/vegetable purees with ≤2% pulp sedimentation, compatible with 8°-32°Brix ranges.

3. Paste & Jam Systems
High-shear processing for particle sizes ≤2mm, suitable for 40°-85°Brix viscosity products.

4. Coconut Water Series
Aseptic filling for clear coconut water (pH 5.0-6.5) and 3:1 concentrate variants.

5. Coconut Derivatives
Stable emulsification for:
✓ Coconut milk (18-24% fat content)
✓ Coconut cream (25-35% fat content)

6. Acidic Liquid Specialization
- Low-acid (pH ≥4.6): Dairy alternatives, plant proteins
- High-acid (pH ≤4.6): RTD teas, fermented beverages

7. Syrup Applications
Precision dosing for:
✓ Simple syrups (1:1 ratio)
✓ Flavored syrups (0.5-2.0% flavor load)

8. Soup & Broth Lines
Multi-phase blending for:
◆ Cream soups (≤12% fat)
◆ Clear consommes (≤0.5% turbidity)
◆ Particulate soups (≤15mm chunks)

Parameters

Name	Single head Aseptic Bag in Drum Filling System	Double head Aseptic Bag in Drum Filling System	Bag in box Single head Aseptic Filler	Bag in box Double head Aseptic Filler	BIB & BID Single head Aseptic bag Filling Machine	BIB & BID Double head aseptic bag Filling Machine	BID & BIC Single head Aseptic liquid Filling Machine	BID & BIC Double head Aseptic liquid Filling Machine
Model	AF1S	AF1D	AF2S	AF2D	AF3S	AF3D	AF4S	AF4D
Bag Type	BID		BIB		BIB & BID		BID & BIC
Capacity (t/h)	up to 6	up to 12	up to 3	up to 5	up to 12	up to 12	up to 12	up to 12
Power (Kw)	1	2	1	2	4.5	9	4.5	9
Steam Consumption (kg/h)	0.6-0.8 Mpa≈50(Single head)/≈100(Double head)
Air Consumption (m³/h)	0.6-0.8 Mpa≈0.04(Single head)/≈0.06(Double head)
Bag Size (Liter)	200, 220		1 to 25		1 to 220		200, 220, 1000, 1400
Bag Mouth Size	1" & 2"
Metering Method	Weighing System or Flow Meter		Flow Meter				Weighing System or Flow Meter
Dimension (mm)	170020002800	330022002800	170012002800	170017002800	170020002800	330022002800	250027003500	440027003500

Guarantees & Services of Aseptic Bag in Drum Filling System

1. Food Safety Compliance
✓ All food-contact surfaces: FDA/EC1935-certified SUS304 stainless steel
✓ Non-contact framework: IP65-rated powder-coated steel
✓ Seal materials: FDA 21 CFR 177.2600 compliant EPDM/Silicone

2. Value Engineering Solutions
◆ TCO（Total Cost of Ownership）optimized designs
◆ ≤15% energy saving vs. industry benchmarks
◆ Modular architecture for ≤30% expansion cost

3. Technical Partnership Program
- Phase 1: 3D process simulation & DFM（Design for Manufacturing）analysis
- Phase 2: CE/PED/3-A compliant mechanical drawings (AutoCAD/SolidWorks)
- Phase 3: FAT documentation package (IQ/OQ/PQ protocols)

4. 360° Support Ecosystem
✓ Pre-sales: Raw material analysis lab services
✓ Implementation: CIP/SOP workflow optimization
✓ Post-sales: Predictive maintenance algorithms

5. Turnkey Implementation
◆ 14-day installation timeline (from EXW to commissioning)
◆ Bilingual training modules:
- Operational: GMP/HACCP compliance
- Technical: PLC programming basics
- Maintenance: Spare parts management

6. Service Commitment
✓ 12-month comprehensive warranty (incl. wear parts)
✓ ≤4hr remote response / ≤72hrs onsite support
✓ Lifetime software upgrades (v2.0→v5.0 compatibility)
✓ ≤3% downtime guarantee with AMC plans

Company Strength

EasyReal Tech. is a leading manufacturer of fruit and vegetable processing line equipment, offering tailored turnkey solutions from A to Z, designed to meet each client's specific needs. Among our core products, the Aseptic Bag-in-Drum Filling System stands out as the most popular. This machine has earned multiple patents and is widely praised by customers for its safety and reliability.

To date, EasyReal has achieved ISO9001 quality certification, European CE certification, and the prestigious State-certified High-tech Enterprise honor. Through long-term collaborations with internationally renowned brands such as Germany's STEPHAN, Germany's RONO, and Italy's GEA, we have developed over 40 pieces of equipment with independent intellectual property rights. Our products have been trusted by major corporations including Yili Group, Ting Hsin Group, Uni-President Enterprise, New Hope Group, Pepsi, Myday Dairy, and more.

As EasyReal continues to evolve, we now offer comprehensive one-stop services that cover everything from project consultation and process development to solution design, construction, and after-sales support. We provide customized services tailored to the unique needs of each client, striving to deliver projects that exceed expectations.