How to eliminate cardboard from yoghurt filling hall?

In order to create yoghurt filling hall as a high hygienic zone,  I'm looking for a solution to de-box primary packaging (tubs, foils, lids) prior entering the filling hall. Does anyone have any ideas of how to eliminate the cardboard? I'm thinking of a trolley, but can't design a suitable one.

I think maybe something like a bottle unscrambler or jar unscrambler would work.  Do an internet search for "jar unscrambler."  Such a machine is meant to unpackage large cases of containers and set them on a line in an orderly fashion.  Most of these can be fitted with an ionized air rinse for the container in order to remove any cardboard particles (or similar foreign matter particles) that could cling to the container.

In order to create yoghurt filling hall as a high hygienic zone,  I'm looking for a solution to de-box primary packaging (tubs, foils, lids) prior entering the filling hall. Does anyone have any ideas of how to eliminate the cardboard? I'm thinking of a trolley, but can't design a suitable one.

So I'd have a low risk deboxing area.  Ideally anything should be in a sealed bag within the box which you can then sanitise through a sanitiser tunnel.  If not, I did see one example for dried fruit where they had a cool layout where they had a tote bin in high care then the wall from low risk went over the top of the tote bin.  So if you can imagine the tote bin slotting in under a kitchen worksurface with a hatch in the top so the dried fruit was very carefully, without handling, tipped through into high care.

If that doesn't make sense I'll draw a picture!

You could have foils delivered in plastic blisters instead of cardboard sleeves, though there would be a cost of tooling and plastic blisters would be more expensive than cardboard.  Depends on the number of sizes.  Also not good for the environment unless returnable and that would be a logistical and hygiene headache.  Though would be the best option for keeping foils intact through delivery to machine and no cardboard.

Or for the foils they could be packed into plastic bags and then inside the cardboard sleeves and you could take them out of the cardboard sleeves for production. Maybe some stacking system on a trolley, but risk of damage transporting.

Or the foils could be packed in plastic bags only and then have cardboard dividers in the outer box instead of carboard sleeves.

Tubs and lids could just be in liner bags.

When i worked in yogurt production, we decanted outside the packing hall into large plastic dolly's, we also had Ecolab Airspexx atomisers in the area of the filling heads to reduce mould potential.

When i worked in yogurt production, we decanted outside the packing hall into large plastic dolly's, we also had Ecolab Airspexx atomisers in the area of the filling heads to reduce mould potential.

Was it plastic dolly's on wheels? Any particular brand? Also regarding Ecolab Airspexx atomisers - is it a mobile spray unit? Did you spray the nozzles or just inside of the filler or around the filler?

So I'd have a low risk deboxing area.  Ideally anything should be in a sealed bag within the box which you can then sanitise through a sanitiser tunnel.  If not, I did see one example for dried fruit where they had a cool layout where they had a tote bin in high care then the wall from low risk went over the top of the tote bin.  So if you can imagine the tote bin slotting in under a kitchen worksurface with a hatch in the top so the dried fruit was very carefully, without handling, tipped through into high care.

 

If that doesn't make sense I'll draw a picture!

Can you please draw a picture?

The Dolly's were just a generic brand on wheels (which were spray sanitised prior to entry), the Airspexx unit was a mobile unit spraying into the atmosphere. However we also looked at the potential for using a fixed unit to spray into filling heads in the bottling hall on site. both were equally as effective.

One of the issues I came across was the handling of opened packaging, any unused pots/lids must be removed and re-sealed before taking away from the area. We had issues with pots blowing within shelf life when we tried storing the opened containers/lids/foils in the room even though they were in sealed containers. Staff handling and cleaning is paramount to prevent mould and yeast issues in this kind of environment.

Is it in an environmentally controlled area - chilled with positive air, if so Airspexx will for the large part be unnecessary but staff control is critical.