RG280: reliability and safety validated by new tests on hydrogen peroxide residues and emissions

The RG280 filling machine is one of the most sophisticated filling solutions developed by Galdi for food safety, efficiency and reliability of the gable top carton packaging process.

Designed according to the principles of hygienic design and created to guarantee high standards of hygiene throughout the entire production cycle, the filling machine uses 35% hydrogen peroxide (H₂O₂) to disinfect packaging. It incorporates systems designed to monitor residues in cartons and emissions in the operational area surrounding the machine, ensuring optimum protection for the product and the operator.

The high standards of hygiene maintained are intended to preserve the quality and organoleptic properties of the product throughout the entire packaging process while ensuring safety for operators working in close proximity to the machine.

Easy sanitisation and precise control of process parameters help to make the RG280 a high-performance solution that meets the strictest requirements of the contemporary food industry.

Further in-depth tests were carried out as part of the process validation activities in order to assess the monitoring efficacy of hydrogen peroxide residues in cartons and of emissions into the atmosphere during machine operation.

• Residual hydrogen peroxide in cartons: after the disinfection process, tests showed that the levels of hydrogen peroxide in cartons were negligible and practically zero, well below the limits set out in FDA regulation 21 CFR 178.1005 on the use of H₂O₂ in food contact materials. The results confirm the high efficacy of the disinfection process in ensuring a significant reduction in the microbial load while maintaining hydrogen peroxide levels in the product close to zero, thereby protecting the quality and characteristics of the end product.

• Hydrogen peroxide emissions in the operational area: monitoring was extended to the operator’s work area whilst the machine was in operation, under various operating conditions (standby, production and washing), by strategically positioning sensors around the filling machine. In all the configurations tested, the measured values were 0 ppm, well within the occupational exposure limits set by current legislation.

These results objectively confirm the high level of process control and the efficacy of the 35% hydrogen peroxide management systems incorporated in the RG280.

Overall, the findings reinforce the position of the RG280 as a reliable and safe solution, which combines production performance, product protection and a focus on the work environment.

The test results validate that the filling machine’s robust design and the efficacy of the engineering decisions made by Galdi, are reflected in high standards of safety, reduced emissions and maximum repeatability of the production process.

A further example of RG280 technology in practice is provided by the experience of Mila, a dairy cooperative in northern Italy, which has installed two RG280 filling machines for packaging its products.

This example confirms that the solution is suitable for production environments requiring high standards of hygiene, where monitoring process parameters, preserving organoleptic properties and compliance with food safety requirements are key factors. Using Galdi technology is a step towards ensuring maximum packaging reliability while preserving product characteristics.

Contact the Galdi team for further information on the RG280 filling machine and gable top carton packaging solutions.