Protecting product integrity and reducing energy costs
The number of tubes produced in Europe in 2018 reached 15.5 billion units. This is a record figure. Annual consumption worldwide can exceed 30 billion tubes. The Germany-based company Karl Höll GmbH & Co. KG has been part of the Alltub Group since 2016 and produces laminate tubes. The company's products are intended mainly for the pharmaceutical market, where high manufacturing-quality requirements apply. To achieve high-quality compressed-air treatment, the manufacturer uses Donaldson's high-efficiency filtration technologies.
The Alltub Group, one of the largest manufacturers of aluminum and laminate tubes, owns six production facilities. Aluminum and laminate tubes are becoming one of the most popular types of packaging. The characteristic features of the tubes correspond to the modern lifestyle: they have a convenient shape, an attractive design characteristic of the brand, are pleasant to the touch, safe during storage and transport, and can hold from a few grams to more than 200 grams of product. Laminate tubes provide optimal protection of the contents thanks to thin layers of aluminum or ethylene-vinyl alcohol copolymer (EVOH). Films only 0.006 mm thick protect the contents of the tube from the effects of light, oxygen, moisture, microorganisms and foreign odors. The taste-neutral barrier layer keeps the volatile components of the tube's contents from escaping, for example flavorings and active ingredients.
This explains the long shelf life of the tube's contents even without the addition of preservatives and other additives.
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The pharmaceutical and cosmetics market places special demands on packaging. To ensure compliance with the high quality requirements placed by manufacturers of medicines and cosmetics on tubes in a wide range of sizes, in 2018 the Alltub Group invested in class 8 cleanroom equipment for the production of laminate tubes at the plant in Germany. All laminate-tube production lines are certified in accordance with good manufacturing practices defined by the ISO 15378 standard.
For the energy-efficient production of compressed air taking consumption into account, a new 75 kW screw compressor and a refrigeration dryer are used. Per month, the compressor consumes about 20,000 kWh of electrical energy and produces up to 800 m³/h of compressed air. This reflects the high demand of the tube production lines for compressed air.
Jürgen Fuhrmann, head of the quality-control department, noted: "We carefully control the supply of compressed air to the production lines. We place the highest demands on the quality of the compressed air. To prevent microorganisms, solid particles, moisture and oil aerosols from reaching the end points of consumption, we use LifeTec™ P-SRF sterile filters to protect part of the production lines in the cleanroom."
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"We are in constant contact with customers working in the pharmaceutical industry and we know that they monitor the quality of compressed air just as strictly. We agreed that sterile filters make it possible to achieve the required reliability."
Nicolo Gagliardi, laminate-tube production manager
Long-service-life filters for protecting the integrity of the product and processes
In the C, V and X versions, the LifeTec P-SRF filter elements are pleated depth filters with inner and outer sleeves and end caps made of stainless steel. The borosilicate filter material with a PTFE coating is supported by a PTFE material.
All filter components meet the requirements of US and European standards for materials in indirect contact with food products, in accordance with Title 21 of the US Code of Federal Regulations and Regulation EC/1935/2004.
The filter's retention rate exceeds 99.99999995 % for particles 0.2 µm in size and 99.99999995 % for particles 0.02 µm in size. According to testing in accordance with the DIN EN 1822 standard, the retention rate for nanoparticles (0.003 µm) exceeds 99.999999991 %.
The LifeTec P-SRF filter elements are characterized by a high retention rate and a long service life
Donaldson's research and development department succeeded in significantly extending the service life of the sterile filters of this series and guaranteeing the high retention rate necessary to protect the integrity of the product and processes. This was achieved through the use of the latest filter material, advanced processing technologies and the optimization of mechanical strength and thermal resistance. These improvements became an important factor for those responsible at the Alltub Group. Nicolo Gagliardi noted: "Replacing the filters after 6 months provides a significant safety margin. After replacement, the integrity of the filter elements is checked by Donaldson specialists."
The Alltub Italia Group successfully uses the extensive experience accumulated by Donaldson in the field of compressed-air filtration technologies. At the plant located in the commune of Cividate al Piano (Bergamo), aluminum tubes are produced, intended mainly for packaging tomato paste. Under a service contract, Donaldson's Milan branch assists the plant in ensuring a safe supply of compressed air, including through the use of the latest generation of energy-saving compressed-air filters.
