Blow-fill-cap combiblock: PET beverage filling and capping machine fed directly by a stretch blow moulder

01

Size the block: blowing cavities, filling stations and capping heads for the rated output

In a combiblock the blow moulder, filler and capper run as one machine, so each section is sized together. KHS's data sheet for the InnoPET BloFill stretch blow molder/filler/capper monoblock (edition 9/7/15) lists up to 81,000 bph for still beverages and up to 72,000 bph for carbonated beverages, a blow molder of 8–36 cavities, 40–144 filling stations for still beverages and 48–192 for carbonated beverages; the capacity figures carry an asterisk in the data sheet. [1]

At the smaller end, MIC lists a blowing filling capping machine with 8 blowing, 32 filling and 10 capping positions, a rated capacity of 18,000 BPH for 600 ml bottles, gravity filling and 200 kW installed power. [3] Wanplas lists nine BFC Combi-block models from the CGX6-32-10 to the CGX24-80-30 with theoretical capacities of 14,000 to 48,000 bottles per hour for a 500 ml bottle. [2]

Editorial calculation: MIC's 18,000 BPH from 8 blowing positions is 18,000 ÷ 8 = 2,250 bottles per hour per position, and 18,000 ÷ 32 = 562.5 bottles per hour per filling position; at 600 ml it delivers 18,000 × 0.6 = 10,800 L/h of beverage. Wanplas's 48,000 B/H is 800 bottles per minute.

KHS lists low-foam filling at filling temperatures of up to 20 °C for carbonated soft drinks, a volumetric filling system with fill levels determined by IFM, an airlock in the transfer area to the filler, and separation of the wet and dry areas. [1] Editorial note: ask each supplier whether its rated output applies to still or carbonated product and to which bottle size, because KHS publishes different maxima for the two and Wanplas states its figures for 500 ml.

Give the supplier the beverages (still or carbonated, fill temperature), bottle sizes with drawings, preform drawings and weights, neck finish and closure, and the output you need at each bottle size.

02

Check the bottle, preform and utility envelope

The block accepts only bottles and preforms within its stated limits. KHS lists bottle content of 0.2–3.0 l, bottle height 120–360 mm, bottle diameter 40–125 mm, filling temperature 4–20 °C and fill level accuracy of s = 1.0–3.0 ml. [1] Wanplas lists 250–2,000/2,500 ml capacity, 340 mm maximum bottle body height, 100/115 mm maximum body diameter, 150 mm maximum preform height and 38 mm maximum bottle mouth diameter for every model in its table. [2] MIC lists bottle diameters of Φ50–Φ92 mm and heights of 150–320 mm for its 18,000 BPH model. [3]

Utilities scale with the model. Wanplas lists installed capacity rising from 170 kW to 320 kW, operating power from 60 kW to 170 kW, compressed air consumption from 4.8 to 15.6 m³/min and weight from 16 t to 29 t across the range, and states that compressed air recovery reaches up to 30% depending on bottle volume. [2]

Editorial calculation: for the CGX24-80-30, 15.6 m³/min × 60 = 936 m³/h of air for 48,000 bottles per hour, about 19.5 litres of air per bottle at the theoretical rate; the CGX6-32-10's operating power of 60 kW is about 35% of its 170 kW installed capacity, so ask for both figures when sizing the supply. [2]

KHS lists options including hot filling, UV treatment, blowout with ionized air, camera quality control, bottle base cooling and dry air in the blow moulding area and the airlock. [1] MIC states that the combined machine "eliminates the need for air conveyors and multiple transfer points" between blowing and filling. [3]

03

KHS InnoPET BloFill and Wanplas CGX ratings in bottles per hour

Published ratings are tied to a stated bottle size or beverage type; compare them on the same basis.

Editorial calculation: the Wanplas CGX6-32-10 occupies 11.0 × 3.6 = 39.6 m² and the CGX24-80-30 occupies 15.0 × 5.3 = 79.5 m², before conveyors, preform feeding and cap feeding. [2]

04

Preform heater, stretch-blow wheel, filler and capper inside one blow-fill-cap block

05

Bottle volume, filling speed, accuracy and capping torque to state for the block

06

Send the bottle, preform and output requirements together

Paste it into your enquiry below or into an email to a maker, then replace every bracket.

Beverages: [still or carbonated; fill temperature]
Bottles: [sizes; drawings; neck finish]
Preforms: [drawing; weight; supplier]
Closures: [type; torque]
Output: [bottles per hour at each size]
Utilities: [voltage; compressed air; cooling water]
Options: [hot fill; UV; camera inspection]

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