Process Engineering

GEA Colby Pty Ltd

328 High Street . Chatswood . Sydney . NSW 2067 . AUSTRALIA
Tel: +61 2 9932 2800 . Fax: +61 2 9932 2801
www.colbypowder.com

GEA Process Engineering Nederland BV

Munsterstraat 5 . 7418 EV . Deventer . Netherlands . EUROPE
Tel: +31 570 66 33 66 . Fax: +31 570 66 33 77
www.gea-pen.nl

GEA Process Engineering Inc.

1600 O’Keefe Road . Hudson . Wisconsin 54016 . USA
Tel: +1 715 386 9371 . Fax: +1 715 386 9376
www.niroinc.com

Colby
 Colby
Modified
Atmosphere
Packing

Colby
 C O L B Y M O D I F I E D A T M O S P H E R E P A C K I N G

S P E C I A L I S T T E C H N O L O G Y F O R F O O D P R O D U C T S

The ongoing challenge HOW COLBY CAN HELP YOU

of packaging foodstuffs
is to efficiently provide
maximised shelf life.
Preservation of food products is one of mankind’s oldest challenges. In modern
manufacturing, high importance is attached to the processor‘s ability to provide
extended shelf life for food products; including powdered or granular products.
Modified Atmosphere Processing (M.A.P.) Systems remove oxygen and replace it with
inert gases.

Colby can help. We can provide a range of M.A.P. systems for all your needs; for both
retail and bulk products. We can apply our proven technology to our equipment or
your existing plant. If necessary, we can even produce specialised designs for specific
customer requirements.

HOW DO COLBY DO IT?

C O L B Y ’ S E X P E R T I S E
Colby uses two main technologies to provide M.A.P. systems for their clients.
Bulk
These are commonly know as 'Post-gassing' and 'Pre-gassing'.

In both methods, oxygen is removed from the product and inert gas introduced as a
replacement. The inert gas is typically nitrogen or a mixture of nitrogen and CO2.
Retail
T H E T R A D I T I O N A L W AY: P O S T - G A S S I N G

Post-gassing is the process of gas replacement 'post' filling; in other words, after the
product has been placed into it‘s packaging.

Pre-Gas Post-Gas This is the most established methodology and Colby has many installations using this
system.

T H E A LT E R N AT I V E : P R E - G A S S I N G

As the name suggests, 'pre-gassing' is the process of atmosphere replacement prior to

packaging. This requires the separate treatment of the product and the container prior
to filling.

E VA C U AT I O N O R F L U S H I N G ?

Both methods have advantages and disadvantages; depending on factors such as

product type, processing speed and cost of inert gases.

Colby has mastered both and can provide you with the right solution for your
packaging needs.

O2

N2 N2 N2 N2 N2 N2 O2 O2 O2 O2

CO2 CO2 CO2 CO2 CO2 CO2 O2 O2 O2 O2

N2 N2 N2 N2 O2 O2 O2 O2 O2
V A C U U M A S T E R

P R O V E N T E C H N O L O G Y T O E X T E N D S H E L F L I F E

W H AT I S T H E C O L B Y VA C U U M A S T E R ?

The Colby Vacuumaster cost-effectively extends product shelf life by removing oxygen
from retail containers of oxygen sensitive powdered and granular products.

Your product will remain fresher for longer because the Vacuumaster achieves very low
levels of residual oxygen.

The system is economic to buy and run. It is simple and compact. It can be tailored to
suit virtually any size range of rigid retail containers and can be designed to suit the
throughput rates of virtually any powder packaging system.

Our technology is used by companies all over the world to extend the shelf life of
whole milk powders, infant formulae, nutritional supplements and other powdered and
granular products.

A PROVEN INERT GASSING SYSTEM

The Colby Vacuumaster uses the time proven method of air

removal and inert gas replacement.

Clinched containers are placed into a chamber which is then

evacuated by vacuum pump so that air is removed from the
container. Nitrogen and/or CO2 is then fed into the chamber,
automatically filling the container with inert gas.

The clinched containers are then conveyed from the chamber to

the final seaming operation.
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 V A C U U M A S T E R

T H E S E C R E T I S S I M P L I C I T Y

Suits high and SIMPLE YET SMART CONTROLS

low throughputs:
Configurations of 1,
2, 3 or 4 chambers or
2 appropriately sized
machines working
The Colby Vacuumaster operates totally automatically. All the operator has to do to
begin daily operation is press the "START" button.
Sensors throughout the system monitor and precisely control all functions through each
cycle.
If a problem should occur, in-built diagnostics will determine the fault, flash a warning
light and advise the operator via the display panel. The source of the fault will be

in parallel, allow displayed and if necessary the machine automatically stopped.

the Vacuumaster to
be tailored to suit
throughputs of 20 to
400 cans per minute.
Changing the container size is as easy as pressing a button. Appropriate pre-set cycle
times and vacuum hold times are automatically determined for each chamber by simply
keying in the number of cans in a row.
Maximum productivity and operator convenience are achieved via a system "PAUSE"
button, which permits operator initiated breaks without requiring complete system
shutdown.

Safety is enhanced with conveniently located emergency stop buttons.

LOWER RESIDUAL OXYGEN

The Colby Vacuumaster achieves lower residual oxygen (R.O.) levels than other systems.
Typically, R.O.’s are less than 1% on packaging and less than 2.5% after seven days.

There are many reasons for this improved performance, such as:

Longer vacuum hold and nitrogen replacement times is achieved (whilst

O2 maintaining high throughput), by use of multiple small chambers.

The unique flow-through chamber design allows gentle loading and unloading to
2 O2 O2 O2 take place concurrently; further improving cycle times.

The Vacuumaster’s continuous process eliminates large batch delays and the
2 O2 O2 O2 O2 resulting need for higher speed can closing.

O2 O2 O2 O2 O2
MINIMAL GAS USAGE
2 O2 O2 O2 O2 The Colby Vacuumaster achieves high chamber volume utilisation, which minimises
inert gas usage, by precisely tailoring chamber size to suit the containers being
O2 O2 O2 processed. There are no guides between individual containers, and for shorter
containers, infills are used to occupy the head space.
O2
 A Simple Semi Automatic System

Fully Automatic Batch M.A.P. System

A SIMPLE COMPACT MACHINE

The Colby Vacuumaster is more compact than conventional machines. The rectangular
shape allows it to fit neatly within almost any layout and containers are delivered and
taken away by simple straight conveyors.

TIME PROVEN TECHNOLOGY

The Colby Vacuumaster's compact, functional design and sheer simplicity offers low cost,
low gas consumption, quick changeover and minimal maintenance.

The system has been used by companies throughout the world since 1974. Leading
brands of components have been used for pneumatic, electrical and mechanical
elements. Should spares or replacements be required, they can be purchased locally
almost anywhere in the world.
P R E - G A S S I N G

M . A . P . T E C H N O L O G Y F O R R E T A I L P R O D U C T S

Powder packaging By eliminating a number of steps from the inert gassing process and reducing the
number of mechanical elements, system reliability and uptime are substantially
specialist, Colby
improved, while the capital cost is significantly lowered.
Powder Systems have
The Colby pre-gassing system is also very space efficient, reducing the requirement
developed a new for environmental control and air-conditioning in new installations and freeing up
type of inert gassing additional space in existing applications.

system for retail

containers PRE-GASSING: HOW IT WORKS

of powdered Pre-gassing involves treating bulk quantities of powder with inert gas, prior to filling
and seaming the container in an inert environment.
products, such as milk
To date, this approach has required all elements of the powder packaging
powders and infant
system, from the bulk supply to the seamer, to be completely enclosed in an inert
formulae. environment.

In addition to requiring large amounts of gas, this approach is prone to delays.

Production must stop any time the inert environment is compromised, due to a
stoppage or service problem. There are also occupational health and safety concerns
associated with oxygen depleted environments.

The Colby system however, is based on a much simpler design, with only the bulk
storage hopper being enclosed. The inert environment in the can is maintained by
the use of patented gassing rails.

As well as providing greater control over the gassing process and simplifying
maintenance and product changeovers, this approach also enables continuous
motion processing, resulting in high productivity rates.

N2 N2 N2 N2 N2 N2 O2

CO2 CO2 CO2 CO2 CO2 CO2

N2 N2 N2 N2

CO2 CO2 CO2

N2 N2 N2 N2 O2
 P O W D E R T R E AT M E N T

The new Colby system uses a purpose-built inert gas exchanger which carefully
modulates the flow of the inert gas, in accordance with the powder feed rate, to
O2 ensure the minimum amount of gas is used while achieving the required R.O. level.

To minimise product segregation, the system uses laminar flow through the powder.
2 O2 O2 O2
Accurate operation is maintained through the use of a large gas infusion surface and
integral oxygen analysers which constantly monitor the R.O. level of the powder and
2 O2 O2 O2 O2
feed the data back to the gas input.

O2 O2 O2 O2 O2
FILLING
2 O2 O2 O2 O2
A major design feature of the Colby system is that it does not require the whole
filler environment to be kept oxygen-free, as the gassing rails are used to control the
O2 O2 O2 atmosphere in the can only. The gassing rails remove oxygen from empty cans to
1,000 parts per million, in a matter of seconds.
O2
 P R E - G A S S I N G

M . A . P . T E C H N O L O G Y F O R R E T A I L P R O D U C T S

FILLING ACCURACY

The process of pre-gassing can cause changes in the density of powders by

compaction and stratification. The Colby system however, carefully regulates the flow
and pressure of the inert gas and utilises a number of sensors throughout the system
to ensure that every can of product meets the most exacting quality standards.

REJECTS

One of the drawbacks with pre-gassing systems has been that it is often difficult to
reject cans without affecting the integrity of the inert environment.

The alternative of rejecting the cans after seaming is not viable.

The Colby system allows cans to be rejected without compromising other cans and
provides a single can gassing station to re-establish the inert environment in the
reject can, after the weight has been corrected.

PRODUCTIVITY

Systems that provide an inert environment by enclosing the complete filler, seamer
and tunnel over a conveyor are difficult to clean and service. They experience high
downtime, as there are always delays while the inert environment is established or
re-established after any stoppage.

Because there are no delays of this type with the Colby system, productivity can be
up to 50% greater than the alternatives.

O2

CO2 CO2 CO2 CO2 CO2 O2 O2 O2 O2

O2 O2 O2 O2
N2 N2 N
O2 O2 O2 O2 O2
CO2 C
O2 O2 O2 O2

N2 N2 N2 N2 O2 O2 O2 O2

O2
Conventional Post-Gassing

Conventional Pre-Gassing

Colby Pre-Gassing
 C O L B Y M A P

T E C H N O L O G Y T O P R O D U C E B U L K M . A . P . P R O D U C T S

A quantum leap in W H AT I S C O L B Y M A P ?

ColbyMap is a proven method of removing oxygen from bulk quantities of

cost effective gassing
powders and granules before they are packed.
technology.
It achieves spectacularly low levels of R.O. at a higher speed and lower cost than
other systems.

It can be used to extend the shelf life of whole milk powders, baby formulaes,
nutritional supplements and other powders and granular products.

The highest product quality can be maintained by gassing it immediately after it

has been produced.

This technique is independent of the next process and can be applied to a wide
variety of packaging systems.
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Pre-gas System (20 tonnes per hour)

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 HOW COLBYMAP WORKS

The extraction of oxygen and injection of an inert

gas has long been recognised as the best way to
improve the product shelf life.

The ColbyMap system uses a vacuum to evacuate

the gassing chamber. Nitrogen is then flushed
through the powder.

Oxygen removal is so effective that even after

several days in bulk storage, R.O. levels as low as
0.5% are achieved.

In a typical 250 kg (550 lb) batch, the entire gassing

cycle takes less than two minutes.

Fill Cycle Vacuum Cycle ColbyMap systems have sophisticated controls that
are pre-programmed and easy to use. The whole
operation is automatic, so results are predictable
and repeatable.

The ColbyMap system is more than just a machine,

it is a versatile gassing system that offers a wide
range of options for bulk storage and packing.

Gas Cycle Discharge Cycle

O2

N2 N2 N2 N2 N2 N2 O2 O2 O2 O2

CO2 CO2 CO2 CO2 CO2 CO2 O2 O2 O2 O2

N2 N2 N2 N2 O2 O2 O2 O2 O2

CO2 CO2 CO2 O2 O2 O2 O2