Under the scorching sun in the eastern desert area of Egypt, the workshop temperature of a date processing factory is as high as 45°C all year round. The dust floating in the air and the humid and hot environment cause traditional packaging equipment to frequently malfunction, and manual operation leads to high product contamination rates. Faced with this common problem in the industry, the ply-pack factory launched a customized solution for aseptic packaging machines in high temperature environments based on the actual needs of Egyptian customers, breaking the production bottleneck with technological innovation.
High temperature adaptability technology upgrade
In response to the desert climate, the ply-pack team has developed a triple protection system for the aseptic packaging machine:
- High temperature resistant motor: Using high temperature resistant motors imported from Japan to ensure that the equipment can operate continuously and stably under 50°C environment;
- Dustproof sealed cabin: The fully enclosed stainless steel body is equipped with a double-layer filtration system to block sand and dust from entering the core sterilization area;
- Intelligent temperature control module: Real-time monitoring of the internal temperature of the equipment, automatic adjustment of the coolant circulation rate, and avoidance of material deformation caused by high temperature.
Automated sterilization process optimization
Traditional manual packaging relies on chemical spraying, which poses risks such as uneven sterilization and excessive residues. ply-pack's aseptic packaging machine achieves full automated sterilization through the following technologies:
- Dynamic sterilization by hydrogen peroxide atomization: Cover the surface of the packaging material with nano-scale atomized particles before filling, with a sterilization efficiency of 99.99%;
- Ultraviolet secondary disinfection: Add UV ultraviolet irradiation in the sealing process to prevent secondary contamination during transportation;
- AI visual inspection: Use high-definition cameras to identify the integrity of the packaging seal and automatically remove unqualified products.
In the Egyptian customer's factory, 30 workers originally had to manually complete the packaging of 20 tons of dates every day, and the return rate of products due to incomplete sterilization once exceeded 8%. After introducing ply-pack's customized aseptic packaging machine:
- Efficiency improvement: A single device can process 25 tons of raw materials in 8 hours, and the production capacity has increased by 120%;
- Cost optimization: Labor dependence has been reduced to 3 people, saving about 150,000 US dollars in labor costs annually;
- Quality assurance: The packaging qualification rate has increased from 92% to 99.5%, helping the product pass the EU export certification.
"In the past, we had to conduct three random inspections on each batch of goods. Now, the machine automatically records the sterilization parameters and sealing data, which can be traced at any time." said the company's quality director.
To ensure the smooth implementation of the Egyptian project, the ply-pack factory has built a multinational agile supply chain:
- Localized adaptation: Cooperate with local parts suppliers in Egypt to provide Arabic operation interface and fast maintenance services;
- Global resource integration: Key components use German high-temperature resistant bearings and Swiss precision sensors to ensure that the equipment life is extended by 30%;
- Remote operation and maintenance system: Through the IoT Internet of Things platform, the Chinese technical team can diagnose the equipment status in real time and provide solutions within 2 hours.
As the global food and pharmaceutical industry has become more stringent in terms of aseptic standards, the ply-pack factory is replicating the experience of the Egyptian case to other high-temperature and high-humidity areas. In the future, aseptic packaging machines will further integrate:
- Energy recovery technology: Use the waste heat of the equipment to heat the factory and reduce the overall energy consumption;
- Modular design: Customers can freely combine filling, sterilization, and sealing units to meet the production needs of multiple categories.
From the banks of the Nile to tropical factories in Southeast Asia, more and more companies are using ply-pack aseptic packaging machines to transform the disadvantages of high temperature environments into advantages in quality control. This is not only an innovation in production technology, but also a common leap forward in the safety and efficiency dimensions of the global industrial chain.
