Food manufacturers often need to add a microbial control stage without rebuilding an existing production line. Limited installation space, conveyor speed, product geometry, cleaning requirements, and operator safety can all affect the design of an ultraviolet treatment system.
This case study describes how UVL selected a compact UV conveyor irradiator for treating plastic bottle caps at a food production facility.
Project Requirements
A food manufacturer in the Komi Republic asked UVL to select equipment for disinfecting plastic caps used with PET bottles.
The UV treatment zone had to be installed directly above the existing cap conveyor. The customer wanted to introduce an additional disinfection stage without changing the conveyor structure or disrupting the established filling process.
The initial technical information included:
application: food production;
treated product: plastic caps for PET bottles;
line capacity: approximately 4,000 caps per hour;
available treatment length: approximately 680 mm;
installation area: an operating production zone with personnel nearby.
These conditions made a large standalone sterilizing conveyor system unnecessary. The more practical solution was a compact UV unit designed for integration into the available section of the existing line.
Installation Challenges
The main difficulty was the geometry of the installation area.
A curved UV irradiator was initially considered because the conveyor section offered limited mounting space. However, manufacturing a custom-shaped unit would have increased the complexity of the project and was not justified until the actual dimensions had been evaluated.
UVL engineers reviewed the available treatment length, conveyor arrangement, cap trajectory, and mounting points. The assessment showed that a standard rectangular irradiator could be installed above the caps without modifying the main conveyor assembly.
Several operational factors also had to be considered:
the UV source had to cover the cap treatment area;
the housing had to be suitable for routine sanitation;
the unit had to fit within the available 680 mm section;
the equipment had to operate near production personnel;
glass contamination risks had to be reduced;
maintenance access had to remain practical.
Because the irradiator would operate in a food-processing environment, the lamp was specified with anti-shatter protection. If the lamp is accidentally damaged, this protective layer helps contain glass fragments and reduces the risk of contamination.
Selected Equipment
The final configuration was based on the UVL AERO VOSUV 1-85 conveyor UV irradiator.
The unit is installed above the moving line and exposes the plastic caps to germicidal ultraviolet radiation as they pass through the treatment zone. This makes it possible to add UV disinfection of packaging components directly to an existing production process.
The equipment includes:
a stainless-steel housing;
one germicidal UV lamp;
an electronic ballast;
electrical connection components;
an anti-shatter lamp coating.
Stainless steel was selected because it is suitable for hygienic production environments and can be incorporated into established cleaning procedures.
Before manufacturing began, UVL and the customer confirmed the dimensions of the irradiator and its proposed position above the conveyor. The resulting design could be mounted within the available space without changing the operating principle of the filling line.
Why a Standard Unit Was Used
Custom equipment is sometimes necessary when a conveyor has an unusual shape or when several sides of a product must be irradiated simultaneously. In this case, dimensional verification showed that a standard unit could provide a more straightforward solution.
Using an existing UV irradiator design offered several advantages:
shorter manufacturing time;
simpler installation;
predictable maintenance requirements;
no unnecessary changes to the conveyor;
easier replacement of the germicidal lamp and electronic ballast.
The equipment was manufactured and prepared for shipment after the final configuration had been approved. Delivery took eight working days from receipt of payment.
Commissioning Support
After installation, the customer sent photographs of the completed assembly. UVL then provided additional operating and connection recommendations.
One of the questions concerned the possibility of connecting another UV lamp to the installed electronic ballast. UVL confirmed that the supplied ballast was designed for one lamp only. A second lamp must not be connected to the same ballast unless the power supply is specifically designed and rated for that configuration.
This clarification is important because an electronic ballast must match the electrical characteristics and number of connected UV lamps. An unsuitable connection can prevent correct lamp operation, reduce output, or damage electrical components.
Benefits of the Installed Solution
The project provided the customer with a compact treatment stage that could be incorporated into its existing production process.
The main benefits were:
direct UV treatment of caps on the operating filling line;
no need to rebuild the conveyor;
no chemical disinfectant applied during this treatment stage;
compact installation within a restricted area;
stainless-steel construction suitable for a food-production environment;
reduced glass contamination risk due to the anti-shatter lamp coating;
straightforward servicing using a single lamp and matched electronic ballast.
Safety Considerations
Direct germicidal UVC radiation can be hazardous to the eyes and skin. Any open UV conveyor system installed near personnel must therefore be assessed for shielding, access control, operating procedures, and protection against accidental exposure.
The required UV dose must also be confirmed for the specific product, target microorganisms, conveyor speed, lamp output, distance, and irradiation geometry. Throughput alone does not demonstrate disinfection performance.
These factors should be evaluated during equipment selection and verified under real operating conditions.
Conclusion
This project demonstrates how UV disinfection can be integrated into an existing food-packaging line without developing an entirely new conveyor system.
After evaluating the available space and process parameters, UVL replaced the initial custom curved-unit concept with a standard UVL AERO VOSUV 1-85 irradiator. The equipment was installed above the plastic-cap conveyor and added a compact ultraviolet treatment stage to a line processing approximately 4,000 caps per hour.
Careful dimensional assessment, appropriate lamp protection, correct ballast selection, and personnel safety measures are essential when integrating germicidal UV equipment into an operating food-production facility.
Top comments (0)