Contiflow

Mixing systems
Best-precision mixing and carbonation

Non-alcoholic refreshment drinks are on the road to success. As a result, more and more
flavour combinations are appearing on the market and arousing consumer curiosity. A
flexible line technology which provides a maximum leeway for the beverage
manufacturers is required.

At a glance

− Mixers and carbonators for the production of different beverage types

− Comprising three modules: deaeration, dosing and carbonation
− Up to six different sizes with variable outputs (33 to 100 percent) of
15, 30, 45, 60, 75 and 90 m³/h are available.
− Highly accurate dosing of syrup and CO2 for a lower syrup
consumption of up to 0.2 percent
− Optional: Integration in the Modulfill VFS-M through elimination of
the interface between the filler and the mixer

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The modules in detail

Deaeration Water feed pipe Deaeration tank Stripping gas feed

(optional)

− Water feed to the horizontal deaeration tank via two sets

of nozzles of different sizes
− Deaeration using a single-stage or double-stage vacuum
process and optional support with stripping gas

Benefits to you

− The stripping gas (CO2) provides: accelerated removal of Recirculation in Vacuum pump
the gasses from the water which ensures efficient deaeration stage 2
deaeration
− Reduction of the sealing water consumption to a Overview of the types of deaeration
minimum thanks to a water saving function in the vacuum − Single-stage = residual oxygen content: ≦ 1.5 ppm*
pump. − Two-stage = residual oxygen content: ≦ 0.8 ppm*
− Two-stage + stripping gas = residual oxygen content: ≦ 0.5 ppm*

* At 15 °C and an initial oxygen content of 10 ppm

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The modules in detail

Dosing
Buffer tank
− Buffer tank for removing the gas bubbles from the
Mass flow meter
ingredient
− Efficient register controller: precision control of the syrup
dosing process, thus achieving potentially high raw
material savings
− Recording of the ingredient volume flow rate with a mass
flow meter
− Dosing of up to eight liquid ingredients possible Control
Ingredient feed
valve
Benefits to you

Mixing water and ingredient in the correct mixing ratio

− Precision control of syrup dosing: for a high potential raw
material savings Brix accuracy:
− In all circumstances: ≦ 0.03 °Bx*
− Top product quality due to multi-stage product
− If the production conditions remain consistent: ≦ 0.01 °Bx*
homogenisation

* Described as sigma 1, based on a target brix content of 10 °Bx

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The modules in detail

Carbonation Gas feed with mass flow meter

− The carbonation nozzle ...

− Always operates at a consistent volume flow rate
− Guarantees efficient and consistent carbonation
(independent from the machine output; Carbonation
between 100 and 33 percent) nozzle
− Dosing of up to two gaseous ingredients possible

Recirculation
Benefits to you Recirculation pipe pump

The incorporated CO2 must be dissolved completely before Krones procedure for high-pressure carbonation: > 8 bar
the filling procedure can be faultless. This is guaranteed CO2 dosing accuracy:
through the combination of high-pressure carbonation − In all circumstances: ≦ 0.08 g/l*
(> 8 bar) in the Contiflow and gentle product transfer to the − If the production conditions remain consistent: ≦ 0.04 g/l*
filler.

* Described as sigma 1

5 Contiflow
The modules in detail
Integrated product tank

The product tank integrated in the Contiflow ...

− decouples the deaeration, mixing and carbonation processes from

the filler,
− balances out production fluctuations,
− ensures that the filler is evenly and consistently supplied with
product – and this at a continuous production output.

In detail

− Adjustment of the production output in the Contiflow:

Recirculation pipe
between 100 and 33 percent of the nominal output
− For a consistent product quality: multi-stage product
homogenization during production
Process monitoring in the recirculation line:
− Recirculation carbonation: about 25 percent of the product
Brix, CO2 and alcohol values of the finished mixed drink are measured inline.
circulates through a short bypass pipe within the CO2 dosing pipe
(loop).
− During the inflow into the carbonation tank:
approximately 6 percent of the entire product volume
permanently recirculates at the carbonation tank discharge.

6 Contiflow
If required: available in the new machine design

Following the sale of more than 1,500* systems all over the world, Krones has now optimised the
Contiflow. The new design stands out because of its numerous benefits: 1 An open and easily accessible
mixing station design thanks
to the stainless steel circular
tube frame

2 A drainage pan is mounted

on the base frame to
combine all of the waste
4 water and drain it off from a
central position

3 Easy-to-maintain design: e.g.

pumps are mounted on a
moveable slide so that the
1 mechanical seals can be
replaced quickly; all pumps
3 are installed close to the
ground
2
4 Reduced construction height:
container dispatch possible
* As of: 2022

7 Contiflow
Part of the new machine design
Easy operation thanks to Connected HMI

The Contiflow is equipped with the new Connected HMI. The platform
ensures that operators can easily communicate with the system in split
seconds.
− Individual dashboard: widgets for a quick overview and direct
access to the daily tasks
− Finding instead of searching: efficient faceted navigation optimised
for all user groups
− Fast learnability: uniform design and interaction principles
throughout all views and for all machines

Benefits to you

− Connected: maximum degree of networking between the machines

and connection to superordinate IT systems
− Secure: powerful against external threats, state-of-the-art IT
security devices
− User-friendly: clear and innovative navigation structure for intuitive
operation

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Multi-ingredient mixing
Overview

Multi-ingredient mixing or conventional variant with pre-manufactured syrup? An important decision as the two concepts for beverage
manufacture require a different system concept in the syrup room.

Conventional mixing with pre-manufactured syrup Multi-ingredient mixing

Preserving agent Preserving agent

Flavouring Flavouring

Essence Essence
Syrup Citric acid
Citric acid
Basic medium* Basic medium*

Sugar Product Sugar Product

Water Water

* Colour, flavouring, plant extracts, acid

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Multi-ingredient mixing
A concept with multiple benefits

Inexpensive production More transparency

The individual ingredients can be handled more individually – for The concept makes improved traceability possible from the raw
example during purchase, transportation and storage. material to the filled bottle.

No need for the conventional syrup room Easy capacity increase

In particular when it comes to carbonated soft drink or shandy The direct feeding of the sugar to the Contiflow makes it possible
batches on water or beer lines, individual components can be to increase the capacity in existing syrup rooms.
directly connected to the Contiflow via powder dissolving tanks or
intermediate bulk containers.

Fewer product losses Increased flexibility

In contrast to ready-to-use syrup, the final mixing of the ingredients Changes to the production program can be handled and
is not performed in a large batch tank. The individual flows can be implemented with great flexibility.
stopped in a targeted manner during production stops or
downtimes.

10 Contiflow
Multi-ingredient mixing
Overview

CO2

Preserving agent

Flavouring

Essence

Citric acid

Basic medium*

Sugar

Water

* Colour, flavouring, plant extracts, acid

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Quick product change-over within ten minutes

The product is changed over entirely without any operator intervention

and offers the highest level of production flexibility.

Fully-automatic process between:

− Syrup room
− Mixer
− Filler

Mixer with memory function

− Entry of the next product and time by the operator

− Reliable product change-over without any manual intervention

For quick product change-overs, the filler requires:

− Additional drain valves

− A separate water connection
− An increased inert gas flow rate

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Additional equipment

− Quick product change-over within ten minutes

− Production protocol
− Extensive measuring devices for: conductivity (water/product),
Brix (incl. sugar inversion), CO2, O2, alcohol, ...
− Gas sterile air filter
− Additional dosing devices in the product discharge:
− For the smallest quantities, e.g. flavouring for flavoured water
− For fruit pieces/inclusions
− Finished-product connections for directly transferring the product to
the subsequent machine
− PHT cooling unit for the finished product
− Sensors for pending maintenance and for the recording of
media/consumption data
− Equipment for reducing media consumption:
− Sealing water cooling of the vacuum pump with external coolant
− Sealing-water cooling with product water in reverse flow
− CO2 saving function for superimposed gas at the carbonation tank

13 Contiflow
Possible additional equipment
CIP module

If the cleaning circuit only comprises the filler and the Contiflow mixer,
it is possible to integrate a CIP module:
− Operates according to the principle of “lost CIP”: cleaning media is
discarded following its successful use
− Controls and monitors the necessary cleaning parameters such as
the flow rate, temperature, concentration, etc.
− Control: The same CIP master control as in the VarioClean; the
system is operated using the touch-screen on the Contiflow or filler
(at the Modulfill VFS-M)

Disinfectant Caustic Acid

Benefits to you

− Targeted cleaning which is independent from the

other machines in the line
Steam/
− No investment in a separate CIP system necessary
− Reduced footprint
hot water
− Increased flexibility

Water
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The Contiflow as part of a holistic sustainability concept
EquiTherm Coldfill

Initial situation

− In the mixer, the product is first cooled down to a filling temperature.

− In order to avoid condensation on the filled containers, they are heated again in
the tunnel heater before labelling.

Energy cycle with the EquiTherm Coldfill

A heat pump provides the mixer and the tunnel heater with thermal energy by ...
− taking on the cooling energy of the mixer,
− bringing it to a higher energy level via electrical energy and
− providing it to the tunnel heater afterwards.

Benefits to you
The system reduces the gas consumption of the heating system and lowers both the
water consumption and the energy required by the cooler. For you, this means: You will
consume significantly less natural resources and save costs at the same time!

15 Contiflow
The Contiflow as part of a holistic sustainability concept
The system structure

Temperature curve
°C

Mixer Filler Tunnel heater

Heating
Cooling

Requirement

Cooler Heat pump Heating

system
Electrical

Electrical
energy

energy
Water

Gas
Supply

16 Contiflow
Integrated mixer as part of the Modulfill VFS-M

Quicker and more compact than ever: in the Modulfill VFS-M, the Contiflow mixer is
connected directly to the filler. This way, the product is transported to the distributor via
the carbonation tank installed at a raised position. The traditional filler bowl is therefore
no longer necessary.
− Reduced media consumption thanks to short mixing phases (no
ring bowl, shorter pipe distances between the mixer and the filler,
optimised pipe routing inside the mixer)
− Reduced CO2 consumption thanks to small head space (no the
ring bowl)
− Loss-reduced filling at the end of production thanks to raised
position of the buffer tank
− Reduced power consumption by use of gravity (product discharge
pump with 11 kW replaced by a recirculation pump with 1.1 kW)

17 Contiflow
Advantages of the integrated mixer

Faster filling speeds Savings*/

Your benefits in figures duration
The direct connection between the Modulfill VFS-M and the Contiflow Less loss during emptying and change-
Up to 30 percent
mixer positively affects the filling duration. The integration in over
conjunction with the raised tank enables up to 250 millilitres to be filled
per second. Fast change-over times during product
<10 minutes
change-overs with LineXpress
Accelerated change-over Space saving thanks to a compact design
10 to 15 percent
and optimised interfaces
You will be well equipped for type and handling parts change-over: the
optimised interface between filler and mixer and the integration of More compact filler clean room design
600 millimetres in
LineXpress minimise the product change-over to less than ten minutes. possible as the product tank is installed on
height
the mixer
Ease of operation, reduced space requirement Lower amount of cleaning agent required
Up to 15 percent
for CIP
As the mixer and the filler are directly connected to each other, they can
share a central HMI. In addition, the valve manifold was reduced and Savings in operating costs Up to 10 percent
integrated in the mixer. The complete process control sensor system is
installed inline. * Compared to line arrangement with separate filler and mixer

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Optional: Integrated syrup supply tank
Prevention of product loss

To prevent waste of valuable syrup in the production

process, it pays to use an integrated syrup supply tank -
especially if the line and syrup room are not located directly
next to each other. A longer syrup feed pipe tends to result
in a larger mixing phase and thus larger product loss.
Especially if the filling line is in stop-and-go mode during
displacement of the feed pipe contents.

Thanks to the integrated supply tank

− Mixing phases which would otherwise have to be drained,
are fed directly into the tank, depending on the tank
content: The Contiflow Brix controller can balance out the
resulting Brix fluctuation in the syrup (depending on the
product and mixture ratio).
− The syrup feed pipe can be emptied with gas instead of
water.
The integrated supply tank directly next to the Contiflow

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Optional: Two syrup supply tanks
Reduction of change-over times

But not only product losses can be minimised with this

supply tank concept. The integration of two tanks instead of
only one can also substantially reduce change-over times.
Often, flushing and the supply of the new syrup to the
Contiflow take longer than Contiflow and Modulfill require
for their own flushing programs. The result: The Contiflow
cannot start production preparations and has to wait – and
valuable production time is lost.
As an option, two supply tanks can be integrated:
− If there is a product change-over, the second tank is
already filled and thereby immediately ready for operation.
− The first tank can then be cleaned without any hurry and
prepared for the next production batch.

20 Contiflow
Optional: CO2 savings function
Savings options

Option 1: Adjusted pressure control

Thanks to the adjusted pressure control during a production stop at the filler, the
Contiflow only remains in production until a fill level is reached in the tank which
requires a CO2 discharge.
Instead of discharging CO2 into the open, the Contiflow will also stop production.
Once the fill level in the tank drops again, production can be resumed quickly. The
continuous supply of the filler with product is thus ensured at all times.

Option 2: Change-over of the production gas

(pressurisation gas change-over)

The use of N2 or compressed air instead of CO2 during production represents a major
savings potential. In this case, CO2 is only used during start-up of the line. Although
there is a possibility of the gas in the tank and the CO2 in the product mixing,
experience has shown that this does not lead to any relevant changes (neither CO2 loss
nor O2 absorption by the product)
It must be assessed whether this function is useful for products which are sensitive to
oxygen.

21 Contiflow
Optional: Water savings function
Savings options at the vacuum pump

Standard feature: Temperature monitoring Water savings per year 1,040,000 l

As soon as the sealing water has reached a certain temperature, fresh water is added Water requirement without
270 l/hour
to the circuit until the temperature drops. This variant is efficient but substantially cooling unit
increases the water consumption as water is permanently being drained. Water requirement with
10 l/hour
cooling unit

Option 1: Heat exchange with external cooling unit Production time

16 hours/day
250 days/year
The sealing water circuit is permanently cooled by a special heat exchanger.
Therefore, an external coolant such as glycol or ice water is required.

Option 2: Heat exchange with integrated heat exchanger Sealing water

discharge
The sealing water is cooled according to the
counter-current principle through a tubular
heat exchanger with deaerated product water. Deaerated Deaerated
No additional coolant is required for this product water product water
discharge
variant. This option can also be retrofitted. infeed

Sealing water
22 Contiflow infeed
Benefits to you

Economical use of syrup Low operating costs

The syrup consumption can be reduced drastically thanks to the The demand of process water is reduced to a minimum by
production at the bottom limit of the Brix range. In addition to that, admitting the sealing water at a later point depending on the
a Brix-value-controlled admission of the syrup prevents the loss of temperature.
syrup dosing the start and the end of production as well as during a
product change-over.

Flexible output Automated processes

The mixer production output can be individually adjusted from 33 to The rinsing function via water or syrup supply starts automatically
100 percent of the rated output. The regulated output results in a already during the production. The operators are relieved and can
reduced gas consumption. focus on other tasks.

Requesting a new machine

You can easily send a request for a
non-binding quotation in our Krones.shop.

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Certified ecological efficiency
Machines with enviro seal

At Krones, the enviro label stands for excellent ecological efficiency. Products that bear the enviro label have proven in an objective test
procedure that they efficiently use energy and media, and that they produce in an environmentally-friendly way. The requirements are defined
by the EME standard that has been developed by TÜV SÜD (technical inspection authority) for assessing production plants. The enviro test
procedure, too, has been certified by TÜV SÜD as an independent expert. Therefore, you can be sure that: an enviro label stands for ecological
efficiency.

This is why the Contiflow is enviro-classified

Energy efficiency
− Use of the latest and optimally designed drives and pumps
Media efficiency
− Minimum water consumption of the vacuum pump due to
recirculation and cooling of sealing water using product water
− Less CO2 losses thanks to saving mode
− Syrup loss is prevented by Brix-controlled syrup feeding (optional)
− High-precision dosing: Reduces the use of expensive raw materials

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Krones total expertise
Precision filling systems for beer and carbonated soft drinks

For PET: For glass: For cans:

Modulfill VFS with PFR valves Modulfill HES Modulfill FS-C

− More flexible and faster thanks to PFR − Beer filling with a minimum oxygen pick-up and − Available both for craft beers and for outputs of up
(Proportional Flow Regulator) technology the lowest CO2 consumption to 135,000 containers per hour
− Highest hygiene level thanks to the Monotec − Minimum change-over times thanks to automatic − Multiple can formats without change parts thanks
design probe adjustment and handling parts that can be to combined centring bells with flexible formats
− Beer filling with a minimum oxygen absorption changed without tools − Servo drive technology for a lower energy
and the lowest CO2 consumption − Short cleaning duration thanks to an automated consumption and higher flexibility
− Modulfill VFS-M: Block synchronisation with exterior cleaning system − Low-maintenance, grease-free main bearing with
mixer for minimum product losses − Highest hygiene level thanks to the Monotec automatic oil-circulating lubrication system
design − Available in a block arrangement with the Krones
Modulseam
− Option: Compact clean room for increased hygiene
requirements

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Everything from a single source

Training sessions at the Krones Academy –

trained personnel for an increased efficiency of Krones Lifecycle Service –
your line Partner for Performance

The multifaceted offer by the Krones Academy ranges from operation, servicing It goes without saying that also after the purchase of new machines, Krones
and maintenance courses through to management training. We will gladly also takes care of your lines: The Krones LCS experts are always there to help you
create your individual training programme. reaching your goals and turn your wishes into optimal LCS solutions.

KIC Krones cleaning agents High-quality components

make your machine shine from Evoguard and Ampco

An immaculate production environment is essential if your product is to shine. Are you looking for shut-off, separation or control valves? For hygienic or
KIC Krones provides you with the optimum cleaning agents and disinfectants aseptic applications? Would you like to have pump technology that perfectly
for each individual production step. fits into your machines? You will find exactly what you are looking for at
Evoguard and Ampco Pumps. The two Krones subsidiaries cover the entire
spectrum of process technology components that you need for high-quality
KIC Krones lubricants production.
for each production step

Whether for gears, chains or central lubrication systems – our greases and oils
are true all-round talents. They can reach every lubrication point, protect your
line and ensure gentle treatment for your products thanks to their food-grade
quality.

26 Contiflow