Albro Powder Filling Machinery

GEA Albro

Powder Filling Machinery

GEA Albro, a subsidiary of GEA Colby, operates from its offices in Kent, United Kingdom. GEA Albro equipment is also distributed through the Americas, Asia and the Far East through sister companies and agencies in more than 40 countries. GEA Albro is recognised as a world leader for the supply of inline and rotary powder filling machinery which is designed for handling both free and non-free flowing products. The GEA Albro filling principles are renowned internationally for: High accuracy Reliability Cleanliness of fill Gentle product handling The special dust free filling principles combined with unique porous insert technology enable products to be handled at speeds in excess of 400 containers per minute. GEA Albro produced its first single head powder filler in 1931. Since then it has grown to become one of the largest and most respected manufacturers of high speed powder systems in over 80 countries. One of GEA Albros existing customers currently fills over 3,000,000 cans of milk and baby formula each day on its GEA Albro fillers. Everyday the world drinks over 200,000,000 cups of instant coffee from jars and cans filled on machinery manufactured by GEA Albro. GEA Albro has supplied well over 200 filling systems worldwide for talcum powder, with over 50 installations to just two customers alone! One reason for GEA Albros success is the special dust free filling principle which enables virtually any container, including narrow necked bottles, to be filled quickly and accurately. GEA Albro supply cutting edge technologies for powder filling systems that are reliable and have minimum downtime. Our systems handle a wide range of products including powdered milks, infant formula, nutritional products, coffee, chocolate custard, instant beverages, talcum and chemicals.

Markets Served by GEA Albro

GEA Albro filling machines have been in operation since 1922. Manufacturers worldwide use our machines to fill an increasing variety of products in the food, cosmetic, pharmaceutical & health care, household and chemical industries. This is achieved by either vacuum or nett weight filling technologies. GEA Albro offer solutions from single units to completely integrated packaging lines specifically designed to satisfy individual requirements, backed up by comprehensive design, manufacturing and after sales service.

Food, Dairy & Powdered Beverage

GEA Albro is internationally renowned for filling all types of food powders, by vacuum or nett weight, into a wide variety of containers including cans, glass jars and plastics. All filling can be achieved with minimal product breakdown and low dust generation. Products filled include milk powders and dairy based powders, coffee, chocolate powder, infant formula, slimming powders, gravy granules, soups, artificial sweeteners, soft drink pre-mixes, powdered spices and custard powders.

Pharmaceutical & Healthcare

Major advances within our machinery development now allow us to handle a wider variety of powdered pharmaceutical products within a sanitary environment. We now handle products which include foot powders, medicated talcum powders, antibiotics and suspension powders.

Cosmetic, Toiletry & Personal Products

GEA Albro has been a worldwide market leader, for over 80 years, for the supply of filling machinery into the cosmetics and toiletries industries. GEA Albro provide solutions to the worlds leading blue chip companies in these fields. We handle products from talc and talc based powders to denture cleaner and powdered toothpastes as well as powders for compacts and makeup.

Household
GEA Albro can offer a variety of filling solutions into this expanding market sector. The household sector has seen an increasing demand for convenient, safe to handle products, in powdered or granular form. Our customers now produce these product forms for household and industrial chemicals and cleaners. We can handle products as diverse as dishwasher powders, laundry cleaners, scouring cleaners, diamond dust and caustic swimming pool chemicals. GEA Albro can fill it for you.

GEA Albro Alpha nett weight filler handling instant coffee.

GEA Albro Delta timed fill powder filler handling talcum.

Powder Filling Machinery

Every type of powder and granule is unique. At GEA Albro we have developed a number of different filling systems to suit specific applications. When GEA Albro offers a particular solution to a powder filling problem the widest variety of factors are taken into account. Whilst the line speed and efficiency of operation are of importance, minimum product damage and high accuracy must be achieved.

Free Flowing Product

A free flowing product is one which will freely flow through an aperture or nozzle under the action of gravity alone. During the filling process this flow has to be controlled as each container is filled. Special filling nozzles have been developed by GEA Albro to ensure the flow of product can be controlled and these technologies include porous inserts and sliding nozzles.

Free flowing products include such products as freeze dried coffee, spray dried coffee, agglomerated coffee, chocolate drink (containing sugar), herbs and spices, dishwasher powder, sugar and salt.

Non-Free Flowing/High Fat Products

A non-free flowing product is one which will naturally bridge within the base of the aperture or nozzle. It may be a powder with relatively high fat levels, for example. Therefore, during the filling process the flow can best be induced, without damage to the product, by the application of vacuum into the container. The result is that the product flows into the container as the pressure equalises.

Non-free flowing products include milk powders, infant formula, talcum powder, cosmetic powders, custard and curry powders, baking powder, cake mixes and icing sugars.

GEA Albro powder filling machinery includes: THETA Rotary Vacuum Fillers DELTA Inline Vacuum Fillers ALPHA Inline Gravimetric Fillers BETA-FIL Nett Weight Fillers

GEA Albro ancillary line equipment includes: Checkweigher Feedback and Reject Systems Product Gassing Systems U.V. Sterilisation Systems Scoop Inserting & Detection Systems Air Cleaners Glue Applicators Rotary Tables & Conveyors Can Seam Inspection Equipment Line Management Control Systems GEA Colby Powder Feed Systems

Vacuum Filling Principle used on Delta and Theta machines

1. Container being raised. Powder bridging in aperture. No vacuum applied.

2. Container in filling position. Fully enclosed circuit is completed. Vacuum is applied, powder bridge is broken and powder begins to flow.

3. Powder level in container reaches gauze, blocking vacuum - powder bridges in aperture.

4. Vacuum tubes connected to atmosphere or inert gas supply. Pressure is equalised so can is released. Can is lowered and powder bridge remains.

Porous Nozzle / Nett Weight Filling Principle used on Beta-Fil and Alpha machines

1. In standby mode, a low vacuum is applied to the nozzle surface creating a suction effect which holds the powder or granules firmly to the inner wall.

2. When a container is placed on the load cell, positive pressure fluidises the inner surface of the nozzle and hopper. This causes the product to flow at high speed into container and also purges the porous nozzle.

3. When 90% of the product has been dispensed in the primary bulk-fill stage, the positive pressure is switched off. The product then continues to enter the container in a controlled manner, but at a much reduced rate.

4. Once the final fill weight has been achieved, a vacuum is again applied to the nozzle giving an immediate and extremely positive product cut off with absolutely no dribble or run-over.

Range of Equipment Supplied

THETA Rotary Powder Filler
The GEA Albro THETA is the flagship of the Albro range. Theta is a vacuum filler suitable for handling freeflowing and non-free flowing products within a wide range of industries. Its state of the art design represents over 80 years of powder filling development. This machine is available in four frame sizes with up to 40 filling heads. Output speeds can be over 400 containers per minute and it will handle container sizes up to 3kg.

Filling Mechanism:
At each filling head a straight vertical tube leads from the hopper directly through the filling nozzle into the containers to be filled. The filling nozzle also incorporates a vacuum tube and a vacuum breaker tube. Although there is no valve, powder is retained in the nozzle until a vacuum is induced when a container is in the filling position. The container then forms an integral part of the totally enclosed vacuum filling circuit. There are no moving parts in contact with the product. The filling cycle commences immediately after the container is lifted against the filling nozzle; the air is drawn out and the product flows into the container from the hopper above. When the powder reaches the desired level in the container, it stops flowing and air or inert gas is let in to release the vacuum. Filling will not take place until a container is in position, or if the container is badly damaged, as the vacuum circuit is not complete.

Features include:
Volumetric Fill, the standard technique for high accuracy filling of a wide range of products No Moving Parts, for minimal product breakdown and no product contamination Self Emptying Hopper, prevents dead zones - minimises cleaning and reduces changeover time Tool Free Change Over, for minimum downtime and maximum uptime Powder Spray Nozzles, to spread filled powder and prevent scoops rising in the container during filling

Optional features include:

Timed Fill Machines, eliminates high variation of fill for liquid powders e.g. Talcum Powder. Pulse Control Fill, for fatty chocolate/cocoa products Individual Head Update, minimises variations in filling head performance, maximising filling accuracy Vibration Facility, provides compaction capability for agglomerated products Top-Up System, to minimise give away for minimum/ nett weight containers Soft Reject, gentle controlled rejection of out of weight containers Gassing System, to maintain the reduced residual oxygen content in the final product.

GEA Albro machines feature sanitary designs and components that can be quickly removed and replaced.

GEA Albro fillers can be supplied with automatic systems for checkweighing and rejecting as well as top up systems for ensuring high accuracy; if required.

DELTA Vacuum Powder Filler

The DELTA range of fully automatic in-line powder fillers have an impressive array of features which provide a level of benefits previously unavailable to the low and medium speed user. DELTA is available with 2,4,6 or 8 heads depending upon product type, volume to be filled and the speed required. The DELTA Filling Principle: Containers are moved into alignment with filling heads while on the integral infeed conveyor. Correct container pitching is ensured through the use of a synchronous indexing conveyor and feed control system. The containers are then automatically pushed from the conveyor onto individual pedestals under each filling head. The pedestals then raise the containers to seal with the filling heads and once an airtight seal has been made, the container is filled. A vacuum is applied to the container, the air is drawn out and the product flows in. When the fill has reached the desired level the product stops flowing and air or inert gas is let in to release the vacuum. The pedestal lowers and the next empty container is moved onto the pedestal. The filling head has no moving components in contact with the product and thereby reduces product breakdown.

ALPHA Nett Weight Powder Filler

The ALPHA range of fully automatic in-line nett weight powder filling machines offer the user a unique combination of simplicity of construction and ease of use. The ALPHA has undeniable market leading performance when it comes to fill accuracy. The machine is ideally suited for accurate filling of free-flowing and semi free-flowing products. The ALPHA range is available with 2, 4 or 6 heads giving output up to 70 containers per minute depending upon product type and volume to be filled. The ALPHA Filling Principle; Containers are moved into alignment with the filling heads by the same method as the DELTA vacuum powder Filler. The difference is the use of fluidised powder feed and individual high resolution weigh cells placed under each filling head. The weigh cells automatically tare the containers to be filled and when the tare is complete the fill is automatically initiated. The filling head has no moving components in contact with the product and thereby eliminates product breakdown.

BETA-FIL Semi-Automatic Nett Weight Filler

This is a semi-automatic powder filling machine which fills to a set weight which is entered by the operator. The operator places the empty container onto the platform, which initiates the fill cycle and removes the full container once the cycle is finished. This machine is suitable for semi-free flowing powders however some difficult powders can be handled with the addition of fluidising, which supplies air or inert gas flow to the feed hopper, to prevent bridging.

GEA Albro Delta 4 head inline powder filler handling dairy powder.

Single head vacuum powder filler handling healthcare powders.

Glue Applicator
These units are specifically designed for jar filling lines where a paper foil membrane is required on the top of the jar after filling. The unit includes a special anti-spill device when the conveyor is not running and can be synchronised to the speed of the container conveyor.

Product Gassing Systems

Inert gas flushing systems to maintain a minimum oxygen content of the packaged goods thus extending the shelf life of the products. The GEA Albro system incorporates product and container pre-gas, gas flushing of filled product and maintenance of the inert environment through until final closure of the container. Gas flushing is undertaken dynamically in the process environment, as opposed to the more traditional batching of cans into gas boxes. GEA Albro can offer varying levels of complexity from totally manual setup through to complete on-line analysis and continuous environment control.

Automatic Scoop Inserters - Mechanical

The automatic scoop inserter features a low level bulk feed reception hopper for easy loading of scoops. A flighted feed elevator supplies a vibratory sorter with a stainless steel bowl. Scoops are discharged through a chute to the placement mechanism which is typically a rotary escapement mechanism. This ensures positive scoop discharge. The inserter is complete with drive motors and all controls and is suitable for most can sizes and scoops. It features continuous, smooth motion with variable speed and no indexing.

Automatic Scoop Inserters - Robotic

GEA Albro can also offer a range of robot based scoop placement systems for your packaging line. These systems utilise a bulk storage and elevator to distribute scoops onto a horizontal belt conveyor that feeds one or more robotic pick and place modules. Scoops on the belt are scanned by a laser profiling or a camera based system that detects their exact position. This co-ordinate position is then fed to the controller which directs the picking module. The robotic dispenser is a versatile system that enables quick changeover between many different scoop types and shapes.

Line Management and Control Systems

The use of control and monitoring techniques enables GEA Albro to offer a totally integrated and synchronised filling system in which individual machines interact through a central programmable controller. This provides the benefit of being able to control the complete system using one master control console which monitors and advises the status of all aspects of the line. An inbuilt management programme gives printouts of line performance and is able to provide a complete analysis of overall operating efficiencies. The result is a system which operates more efficiently with fewer operatives and with less downtime.

Check Weigher Feedback Systems

High resolution dynamic checkweighing systems are integrated into the equipment to provide on-line feedback and machine correction capability. With varying levels of complexity the systems can include tare and/or gross checkweighing with feedback and the ability to have individual head adjustment; which will minimise product giveaway. Along with this unique software there is trend adjustment to compensate for product bulk density. GEA Albro provides state of the art weight control.

GEA Albro Alpha 4 head inline nett weight machine filling coffee jars.

Twin head Beta-Fil nett weight powder filler.

GEA Albro Alpha 3 head inline batching powder filler.

PHARMACEUTICAL & HEALTHCARE

CHOCOLATE & CONFECTIONARY

MACHINE RANGE

FILLERS

THETA ROTARY VACUUM FILLERS DELTA INLINE VACUUM FILLERS ALPHA INLINE GRAVIMETRIC FILLERS BETA-FIL GRAVIMETRIC FILLERS
ANCILLARY EQUIPMENT

CHECKWEIGHER FEEDBACK SYSTEMS MACHINE GASSING SYSTEMS SCOOP INSERTERS GLUE APPLICATORS MANAGEMENT CONTROL SYSTEMS GEA COLBY POWDER FEED SYSTEMS
The data and material depicted in this document are given for reference only and can be changed without preliminary notice

INDUSTRIAL & AUTOMOTIVE

COSMETICS & TOILETRIES

HOUSEHOLD PRODUCTS

FOOD & DAIRY

BEVERAGES

GEA Albro - operating all around the world

Afghanistan Albania Algeria Andorra Argentina Armenia Australia Austria Azerbaijan Bahamas Bahrain Bangladesh Belarus Belgium Bolivia Bosnia Herzegovina Botswana Brazil Canada Chile China Colombia Costa Rica Croatia Cyprus Czech Republic Denmark Ecuador Egypt El Salvador Estonia Finland France Georgia Germany Ghana Greece Guatemala Honduras Hungary India Indonesia Iran Iraq Ireland Israel Italy Jamaica Japan Jordan Kenya Kiribati North Korea South Korea Kuwait Laos Lebanon Libya Lithuania Luxembourg Macedonia Madagascar Malawi Malaysia Mauritius Mexico Morocco Mozambique Myanmar Netherlands New Zealand Nicaragua Nigeria Norway Oman Pakistan Panama Paraguay Peru Philippines Poland Portugal Qatar Romania Russian Federation Saudi Arabia Serbia Singapore Slovakia Slovenia South Africa Spain Sri Lanka Sudan Swaziland Sweden Switzerland Syria Taiwan Tanzania Thailand Tunisia Turkey Turkmenistan Ukraine United Arab Emirates United Kingdom United States Uruguay Venezuela Vietnam Zimbabwe

Part of the
GEA Group.
Albro, Dico and Gravfil are brands recognised all over the world as providers of high quality, innovative packaging machinery. Now owned by GEA Colby, they are part of the worldwide network of GEA Group Companies.

Process Engineering

GEA Albro Unit 3, Plot 7 . Henwood Industrial Estate . Ashford Kent TN24 8DH . UNITED KINGDOM Tel: +44 (0) 1233 629161 . Fax: +44 (0) 1233 639560 www.geaalbro.com

GEA Colby Pty Ltd 328 High Street . Chatswood . Sydney NSW 2067 . AUSTRALIA Tel: +61 2 9932 2800 . Fax: +61 2 9932 2801 www.geacolby.com