PETnology Handbook 2024

The GEA ABF 2.0 is capable of handling a diverse range of sensitive beverages, from still, clear drinks with or without particles, to carbonated drinks - high or low acid. (Photo: GEA/Corrado Frignani)

Aseptic Blow Fill

GEA launches ABF 2.0 filling system for shelf-stable, sensitive beverages and milk-based drinks

The new rotary Aseptic Blow Fill technology from GEA (ABF 2.0) provides beverage manufacturers with maximum hygiene and food safety and top performance in terms of filling speed, accuracy and flexibility.

ABF 2.0 is suitable for the filling of shelf-stable, sensitive beverages and milk-based drinks, using H2O2 for the sterilization of PET preforms. With the ABF 2.0, GEA has used all its experience to optimize Total Cost of Ownership (TCO) while enhancing the control of key parameters to eliminate any potential risk to the product. The ABF 2.0 can fill a full range of sensitive beverages including still, clear drinks with or without particles, and carbonated drinks - high or low acid.

In the 1990’s, when the aseptic systems were enclosed in large white rooms to fill in a sterile environment, GEA launched in the market an innovative way to confine and minimize the air volume to be kept in aseptic conditions around the filler and so to protect the product: the Microbiological Isolator. With the ABF technology launched back in 2010 GEA has confined inside the Microbiological Isolator also the aseptic Stretch Blow molder, thus forming together with the filler and capper module a state of the art system for a product protection with no compromises and providing numerous benefits to users including reduced bottle weight, the option to develop increasingly complex and attractive bottle designs and allowing for the elimination of air conveyors, bottle sterilization and rinsing turrets. The whole system resulted more compact than traditional aseptic technology and required fewer operators.


Most bottling plants handle a wide variety of products so GEA has designed the format changeover system on the ABF 2.0 to be fast and simple. This has enhanced the flexibility of the machine so that it appeals to the widest range of customers especially those with multiple products. As companies work to achieve market share and product variety, the flexibility of plant operations is vitally important. The ABF 2.0 provides the versatility and control that they need.

The environmental cleaning and sterilization processes are completely automated and performed via a control panel without any manual manipulation from operators, that can represent a potential risk of contamination.

Thanks to its successful long-term experience in delivering technologies offering top food safety level, GEA is the only supplier that can propose FDA approved filling solutions for both PAA and H2O2-based applications. Being the evolution of a consolidated, FDA validated platform, the ABF 2.0 is ready to meet all FDA regulations, which represent one of the most stringent protocols.

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