GEA is introducing a new generation of filling technology at drinktec 2025: a modular, service-friendly filler engineered for high-performance beverage production in an increasingly diverse and demanding market. With an upgraded hygienic design and smart features such as AI-assisted interfaces, it aims to boost line efficiency, uptime and daily operations.
Compatible with GEA’s aseptic filling platforms (ABF, EcoSpin, Whitebloc, Unibloc Flex), the new module accommodates still and carbonated beverages, including low- and high-acid products, dairy-based recipes, and sensitive formulations. All core upgrades are embedded in GEA’s new Kinetic Edge Design, which structurally improves accessibility and cleanability. The machine will be exhibited in full size at GEA’s booth as a key highlight of the drinktec showcase.
Modular architecture for growing SKU variety and shorter cycles
Beverage producers today must accommodate more SKUs and faster product turnarounds while maintaining hygiene and efficiency. GEA’s new filler meets these challenges with a modular architecture that adapts to diverse beverage types, bottle formats, and production capacities.
The system connects seamlessly to GEA’s aseptic platforms and can be configured to suit specific production needs. Its upstream and downstream compatibility ensures a cohesive line setup and future-proof scalability.
Designed for PET, aluminum and glass containers, the filler supports multiple closure types including screw caps, sport caps, and aluminum closures. Depending on setup, the system achieves up to 60,000 bottles per hour.
A new gripper mechanism – premiering at drinktec – prevents bottle rotation during capping and enables fully automatic format changeovers between different bottle formats with the same neck finish – without tools, manual adjustments, or parts exchange. The result: faster changeovers, increased overall equipment effectiveness, lower risk of operator error, and less media and energy use by avoiding external cleaning and sterilization.
Maintenance redefined: faster access, less downtime
The new design prioritizes accessibility and maintainability at every level. Each mechanical element has been designed to reduce unplanned downtime and support operator efficiency.
The GEA Kinetic Edge frame plays a critical role here: it opens up key access zones, reduces the number of removable panels, and creates wider, maintenance-friendly service areas.
As a result, technicians benefit from improved component visibility, easy access entry zones, and simplified handling of components during inspections or repairs. New quick-lock access doors further simplify access to the aseptic chamber, reducing both opening time and handling effort.
Hygienic design for faster cleaning and safer processing
Hygiene and product safety are mission-critical for manufacturers of low and high-acid formulations. GEA’s redesigned aseptic isolator is EHEDG-compliant and introduces upgrades to simplify CIP and visual inspection.
All product-contact surfaces have been optimized with steeper slopes, streamlined geometries, and smooth, high-grade finishes. These modifications reduce residue buildup and dead zones, while enhancing cleaning speed and consistency. The sloped isolator ceiling – a first for GEA – ensures that droplets cannot accumulate above the bottle path, mitigating contamination risk.
Smart and secure: AI systems support operators and increase uptime
Digital tools integrated into the new filler are designed to reduce unplanned downtime and support operator efficiency. At the heart of this setup is a new 24-inch HMI with AI-assisted alarm diagnostics. Based on real-world data from GEA’s global installations, the software proposes the most likely root causes and offers clear, prioritized solutions – helping staff act quickly and confidently.
