Ozone Generators Manufactured in Cape Town

Bright Blue CCS Ozone Systems for Prepared Water Disinfection – Ozone Generators Manufactured in Cape Town.

The Bright Blue CCS is an advanced ozone disinfection system specifically engineered for prepared water applications in the bottled water industry. Developed to comply with stringent Coca-Cola standards for brands such as Pump, Bon Aqua, and Dasani, the system delivers reliable, automated water disinfection while integrating seamlessly with modern production environments.

Designed for compatibility with Krones and KHS fillers and blenders through Profinet communications, the Bright Blue CCS provides fully automated operation and precise process control. Since the first unit was introduced in 2001, the system has undergone continuous refinement and improvement, earning a reputation for exceptional reliability and long operational life. With proper maintenance and servicing, a service life of approximately 20 years can be expected.

Designed to Meet Coca-Cola Specifications

The Bright Blue CCS has been developed to meet Coca-Cola specifications for prepared water disinfection, including compliance with Coca-Cola standards for ozonation and electrical equipment. The system is designed to provide four minutes of ozone contact time at a concentration sufficient to maintain an ozone residual of approximately 0.5 ppm after bottling. This process achieves a 5-log microbiological reduction, ensuring high levels of product safety and quality.

In addition to meeting Coca-Cola requirements, the system also complies with EU/CE standards and conforms to Coca-Cola Electrical and Mechanical Standard Specifications.

Advanced Automation and Connectivity

At the heart of the system is a sophisticated automation platform that enables efficient and accurate control of the ozonation process. Bright Blue CCS systems are equipped with 10-inch full-colour touchscreen interfaces that provide operators with intuitive access to all system functions.

Optional Ethernet connectivity allows the ozone generator to be connected to a plant network, enabling remote monitoring and control from a desktop or laptop computer. This functionality gives operators and maintenance teams full access to system controls and diagnostics without needing to be physically present at the unit.

Climate-Controlled for Reliability

To ensure maximum reliability in demanding industrial environments, all Bright Blue CCS systems are climate controlled using integrated Seifert air conditioners. Maintaining a clean, cool, and dry internal environment significantly improves system performance and extends component life.

Clean Operation

The sealed, climate-controlled enclosure prevents dust from entering the panel, helping to keep internal components clean. This not only improves reliability but also simplifies maintenance procedures.

Optimised Cooling

Many installations are located in tropical regions where high temperatures and humidity are common. The built-in cooling system maintains optimal operating temperatures, ensuring stable performance even under challenging environmental conditions.

Moisture Protection

By controlling humidity levels within the cabinet, the air conditioning system protects sensitive electronics from dampness and moisture, helping ensure long-term operational stability.

Built with Operator Safety in Mind

Safety is a core consideration in the design of every Bright Blue CCS system. The systems include multiple built-in safeguards to protect operators and comply with Coca-Cola electrical and mechanical safety standards.

Vacuum Operation for Enhanced Safety

The ozone cells operate under vacuum conditions rather than pressure. In the unlikely event of a leak, air is drawn into the ozone cell instead of ozone escaping into the environment. This design significantly enhances operational safety.

De-Gassing and Ozone Removal

The ozone/water contacting system incorporates a specialised ozone-resistant de-gas valve positioned at the top of the tank. This allows undissolved ozone to be safely vented away from the production area while maintaining tank pressure.

Under normal operating conditions, there should be no detectable ambient ozone within the production environment.

Integrated Ozone Leak Detection

The system includes an interface for two Dräger ozone leak detectors, typically installed in the bottling hall and ozone plant room. These detectors are interlocked with the PLC control system. If ambient ozone levels exceed occupational health and safety limits, the ozone system automatically shuts down and displays a warning to operators.

Precision Ozone Control with PID Technology

The concentration of ozone in the water is regulated using a dedicated PID (Proportional-Integral-Derivative) controller. This advanced control system continuously monitors ozone levels and compares them against the operator-defined set point while also measuring the rate of change.

Based on this feedback, ozone production is automatically adjusted to maintain highly accurate control and stable operation. The ozone set point is also linked directly to the “Ozone OK” interlock, meaning any change to the set point automatically adjusts the interlock threshold accordingly.

Engineered for Long-Term Performance

Bright Blue CCS systems are designed with a strong focus on durability, quality, and reliability. Many customers consider them among the most dependable systems within their plants, thanks to their robust engineering and consistent performance in demanding production environments.

For detailed technical specifications and component information, click here