ESL Filling and Capping0 pages

201 W. Walker St. • Milwaukee, WI 53204
(414) 384-3200 • FederalMfg.com

ESL FILLING & CAPPING OVERVIEW
Several Federal contact level filling systems
are being used in extended life fresh juice
applications to achieve a 70-day refrigerated
code life. These fillers make use of the special
filling valves used on our earlier ESL fillers.
These machines are housed in Class 100
enclosures, possess exterior sanitizing systems,
and have cap and bottle treatment systems
supplied by Federal.
In 2007 we supplied a complete system to a
new organic dairy that bottles fresh milk in
plastic gallons using standard HTST
pasteurizing to achieve a 25-day refrigerated
code life. This dairy has an onsite milking
operation and has strict control of the quality
of their raw supply.

Federal has been involved in supplying
various optional equipment for extended life
since 1995. We have supplied contact-type
fillers with special filling valves and filler bowls
that allowed steam sterilization at 50 psi
(3.447 bar) for 30 minutes. These fillers had
Federal Class 100 enclosures, exterior
sanitizing systems, and systems for treating
the bottles and caps. These systems were
designed to achieve a 50 to 60-day
refrigerated code life.
Next we developed a non-contact, netweight system to achieve a 60-day refrigerated
code life with potential for a higher code life
when it is required (shown in picture).

From the point where the pasteurized milk
discharged from the plate heat exchanger, the
product was handled in the same way as UHT
processed product with storage in an aseptic
tank, lines, and valves with steam trace and
steam or superheated water circulation after
CIP.
The plant installed blow mold machines that
blew sterile bottles and sealed the tops.
Federal supplied a system for removing the
sealed bottle tops inside of a Class 100
environment immediately prior to the filler
which was also enclosed with a Class 100
enclosure. Supplied were special ESL valves
that provided for cleaning the inside and
outside of the filling valve during CIP and
sanitizing the valves and all product contact
surfaces using 96° C water for 30 minutes. We