Serac and Budé Group develop aseptic monobloc technology for aerosol filling

The companies have jointly engineered a next-generation aseptic monobloc filler and crimper system, purpose-built for high-speed aerosol production of whipped cream. This breakthrough combines decades of process technology expertise to create a compact, hygienic, and highly efficient monobloc platform that redefines standards in net weight aseptic filling.

Both Budé Group bv and Serac have long been leaders in the engineering of aseptic production lines for whipped cream in aerosol formats. In response to market demand for a high-speed monobloc solution – integrating filling, valve placement, and crimping into a single compact unit – the two companies pooled their technical knowledge to design a system optimised for both performance and sterility.

Traditionally, aerosol production lines at 200 cans per minute (cpm) separate the filler and crimper onto individual frames with a mechanical transfer screw for synchronisation. However, scaling up to 300cpm required a complete rethinking of this configuration. The resulting monobloc concept delivers enhanced synchronisation, superior aseptic integrity, and minimised mechanical complexity.

Key advancements in the new monobloc technology include:

• Positive can handling:  Starwheel transfers guide cans seamlessly throughout the system, eliminating the need for mechanical screw transfers. This ensures continuous motion and minimises the risk of misalignment.
• Integrated rotary valve application: A rotary turret enables more accurate and controlled valve placement. The turret design, combined with body-guided can holding, ensures optimal alignment and consistent crimping results.
• Monobloc cladding: Sloped cladding optimises surface cleaning and disinfection cycles and has the possibility of automation of cleaning processes. This enhances hygiene and reduces manual intervention, key pillars of advanced process engineering.
• Serac’s multiflow net weight technology: The heart of the filler uses Serac’s proven magnetic valve system, known for its fill accuracy (1σ < 1g/1kg) and hygienic, non-contact filling method. This ensures no cross-contamination and robust sterility during high-throughput operation.
• Simplified changeovers: With automatic height adjustments and diameter parts switch, the system allows for faster, more repeatable changeovers—an essential feature for flexible, multi-SKU production environments.

Serac’s 50 years of innovation in net weight filling, especially in ATEX-rated and hygienically sensitive environments (eg, cosmetics, paints, detergents), aligns perfectly with Budé Group’s strategic focus on aerosol processing. This partnership enables Budé to expand into medium-speed (80-600cpm) aerosol lines for a broader range of products, from high-foaming creams to viscous formulations.

“This filler and crimper can be used across a wide range of aerosol products,” commented Ingeborg Pluim, area sales manager at Serac. “While it was developed with whipped cream in mind, the technology is equally suited to foaming, viscous, or chemically sensitive products.”

With this advanced monobloc as a foundational platform, Serac and Budé are setting the stage for a new generation of process-engineered machines capable of meeting the demands of the modern aerosol market.

In the UK, Evolution BPS works in partnership with Serac, as well as with a range of other original equipment manufacturers (OEMs) across the filling and packaging process. This collaborative approach allows Evolution BPS to deliver integrated, end-to-end solutions tailored to the specific needs of each client, ensuring efficiency, reliability, and innovation at every stage of the process.