U.S. patent application number 09/835965 was filed with the patent office on 2002-02-14 for aseptic product dispensing system.
This patent application is currently assigned to Lancer Partnership, Ltd.. Invention is credited to Schroeder, Alfred A..
Application Number | 20020017321 09/835965 |
Document ID | / |
Family ID | 22525911 |
Filed Date | 2002-02-14 |
United States Patent
Application |
20020017321 |
Kind Code |
A1 |
Schroeder, Alfred A. |
February 14, 2002 |
Aseptic product dispensing system
Abstract
An aseptic product dispensing system generally includes a
sanitary connection assembly interposed in fluid communication with
a substantially conventional aseptic product source and a
substantially conventional product dispenser. The sanitary
connection assembly is provided with an automated cleaning system
whereby a combination of pressurized gas, flushing fluid and/or
sanitizing solution may be injected into, and thereafter evacuated
from, the sanitary connection assembly.
Inventors: |
Schroeder, Alfred A.; (San
Antonio, TX) |
Correspondence
Address: |
LAW OFFICES OF CHRISTOPHER L. MAKEY
1634 Milam Building
115 East Travis Street
San Antonio
TX
78205
US
|
Assignee: |
Lancer Partnership, Ltd.
|
Family ID: |
22525911 |
Appl. No.: |
09/835965 |
Filed: |
April 16, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09835965 |
Apr 16, 2001 |
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09637232 |
Aug 11, 2000 |
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6240952 |
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60148468 |
Aug 12, 1999 |
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Current U.S.
Class: |
137/240 ;
134/169R; 134/95.1 |
Current CPC
Class: |
B08B 9/0325 20130101;
Y10T 137/4259 20150401; B67D 1/108 20130101; B67D 1/07 20130101;
B67D 2210/00013 20130101 |
Class at
Publication: |
137/240 ;
134/95.1; 134/169.00R |
International
Class: |
B08B 009/00; F16K
051/00 |
Claims
What is claimed is:
1. A sanitary connection assembly for providing substantially
aseptic fluid communication between an aseptic product source and a
conventional product dispenser, said sanitary connection assembly
comprising: a body having a first cavity portion interior thereto;
an outlet from said first cavity portion for interfacing with a
product dispenser; a flow port into said first cavity portion from
a second cavity portion; a valve for substantially limiting fluid
flow through said flow port to from without said first cavity
portion to within said first cavity portion; and wherein said body
is adapted for flushing of said second cavity portion.
2. The sanitary connection assembly as recited in claim 1, wherein
said body is further adapted for flushing of said first cavity
portion.
3. The sanitary connection assembly as recited in claim 2, wherein
said body is further adapted for flushing of said first cavity
portion substantially simultaneously with said second cavity
portion.
4. The sanitary connection assembly as recited in claim 2, wherein
said body is further adapted for flushing of said second cavity
portion independently of said first cavity portion.
5. The sanitary connection assembly as recited in claim 4, wherein
said body comprises a flushing inlet for providing fluid
communication of a cleaning fluid to said second cavity
portion.
6. The sanitary connection assembly as recited in claim 5, wherein
said body further comprises a drain port from said second cavity
portion for evacuation of the cleaning fluid from said second
cavity portion.
7. The sanitary connection assembly as recited in claim 6, said
sanitary connection assembly further comprising a source of
cleaning fluid in selective fluid communication, through said
flushing inlet, with said second cavity portion.
8. The sanitary connection assembly as recited in claim 7, wherein
said cleaning fluid comprises a sanitizing solution.
9. The sanitary connection assembly as recited in claim 7, said
sanitary connection assembly further comprising a source of
flushing fluid in selective fluid communication, through said
flushing inlet, with said second cavity portion.
10. The sanitary connection assembly as recited in claim 9, wherein
said flushing fluid comprises water.
11. The sanitary connection assembly as recited in claim 9, said
sanitary connection assembly further comprising an automated
cleaning system.
12. The sanitary connection assembly as recited in claim 11,
wherein said automated cleaning system comprises a first flow
control valve for controlling fluid communication of said cleaning
fluid from said source of cleaning fluid to said second cavity
portion.
13. The sanitary connection assembly as recited in claim 12,
wherein said automated cleaning system further comprises a second
flow control valve for controlling fluid communication of said
flushing fluid from said source of flushing fluid to said second
cavity portion.
14. The sanitary connection assembly as recited in claim 13,
wherein: said cleaning fluid is pressurized at said source of
cleaning fluid; and said flushing fluid is pressurized at said
source of flushing fluid.
15. The sanitary connection assembly as recited in claim 11,
wherein said automated cleaning system comprises a controller, said
controller being adapted to selectively admit said cleaning fluid
and said flushing fluid to said flushing inlet.
16. The sanitary connection assembly as recited in claim 15,
wherein said controller is further adapted to selectively admit
said cleaning fluid and said flushing fluid to said flushing inlet
at a first pressure and at a second pressure, said second pressure
being greater than said first pressure.
17. The sanitary connection assembly as recited in claim 16,
wherein said valve is biased against said flow port, thereby
normally closing said flow port between said first chamber and said
second chamber.
18. The sanitary connection assembly as recited in claim 17,
wherein: said first pressure is insufficient to dislodge said valve
from said flow port; and said second pressure is sufficient to
dislodge said valve from said flow port, thereby enabling flow
through said flow port from said second chamber toward said first
chamber.
19. The sanitary connection assembly as recited in claim 9, wherein
said second cavity portion comprises a cannular projection from
said flow port.
20. The sanitary connection assembly as recited in claim 19,
wherein said cannular projection is adapted to pierce a protective
covering over a hose connector.
21. The sanitary connection assembly as recited in claim 19,
wherein said second cavity portion further comprises an annular
flushing cavity about said cannular projection.
22. The sanitary connection assembly as recited in claim 21,
wherein said flushing inlet terminates into said flushing
cavity.
23. The sanitary connection assembly as recited in claim 22,
wherein said cannular projection comprises a central product
aperture to said flow port.
24. The sanitary connection assembly as recited in claim 23,
wherein said drain port projects into said central product aperture
substantially adjacent to said flow port.
25. The sanitary connection assembly as recited in claim 24, said
sanitary connection assembly further comprising: a hose connector
for joining a product hose to said body; and wherein said hose
connector cooperates with said body to form said second cavity
portion.
26. The sanitary connection assembly as recited in claim 25,
wherein said annular flushing cavity is arranged to project fluids
passed through said flushing inlet toward an interior face of said
hose connector.
27. The sanitary connection assembly as recited in claim 25,
wherein said hose connector comprises a check valve, said check
valve being arrange to substantially prevent passage of fluids from
said second cavity into the product hose.
28. The sanitary connection assembly as recited in claim 9, said
sanitary connection assembly further comprising a source of gas in
selective fluid communication, through said flushing inlet, with
said second cavity portion.
29. The sanitary connection assembly as recited in claim 28,
wherein said gas comprises carbon dioxide.
30. The sanitary connection assembly as recited in claim 29,
wherein said gas consists essentially of carbon dioxide.
31. The sanitary connection assembly as recited in claim 9, said
sanitary connection assembly further comprising a check valve, said
check valve being arranged to prevent fluid flow from said second
cavity portion to said sources.
32. The sanitary connection assembly as recited in claim 31,
wherein said check valve is integral with said flushing inlet.
33. The sanitary connection assembly as recited in claim 9, said
sanitary connection assembly comprising a plurality of check
valves, each said check valve being associated with one of said
sources and arranged to prevent fluid flow toward the associated
said source.
Description
RELATED APPLICATIONS
[0001] This application is a continuation under 35 USC .sctn.120 of
co-pending U.S. patent application Ser. No. 09/637,232 filed Aug.
11, 2000, which claims all available benefit under 35 USC
.sctn.119(e) of co-pending U.S. provisional patent application
Serial No. 60/148,468 filed Aug. 12, 1999. By this reference, the
full disclosures of U.S. patent application Ser. No. 09/637,232 and
U.S. provisional patent application Serial No. 60/148,468 are
incorporated herein as though now set forth in their respective
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to food product dispensing
equipment and, more particularly, but not by way of limitation to a
method and apparatus for the lengthened preservation and safer
dispensing of an aseptic food product with minimum introduction of
contaminants thereto.
BACKGROUND OF THE INVENTION
[0003] As changing consumer lifestyles have increasingly resulted
in an emphasis on speed and convenience, foodborne illness of
microbial origin has become a most serious food and beverage safety
issue. As more consumers rely on manufacturers and food stores for
food-safety protection, food and beverage providers must take
heightened steps to eliminate those risks most often responsible
for foodborne illness. In particular, the food producer,
distributor and retailer must work toward the elimination of
foodborne hazards resulting from improper holding temperature and
post-production contamination, factors that according to the
Centers for Disease Control and Prevention were responsible for
nearly 80% of outbreaks in a recent survey period.
[0004] In the past, food and beverage providers have addressed
microbial-related foodborne illness issues through adherence to
food safety recommendations based upon temperature and acidity.
These guidelines, however, essentially only extend the time
required for a risk to become a hazard, in the case of
refrigeration, or sidestep the problem by categorizing certain
products as too acidic to support microbial activity.
Unfortunately, refrigeration only slows microbial activity and
recent studies reveal that previously established acidity-based
recommendations may not sufficiently eliminate risks from some
pathogens.
[0005] More recently, food and beverage providers have turned to
technological advances in food preparation and handling to address
some of the shortcomings of refrigeration and acidity level based
approaches. One such advance is the irradiation of low acid type
products, such as milk, yogurt and ice cream. In practice, the low
acid product is heated or pasteurized, sealed in a sterile package
and then treated with a radiation source to result in an entirely
aseptic product having a significantly extended shelf life without
requirement for refrigeration. Unfortunately, the known aseptic
products remain free from contamination only to the time of
dispensing, at which point airborne or otherwise introduced
microbial agents restart the spoilage process.
[0006] As a result of dispensing related contamination, even
aseptically produced products require constant refrigeration or
rapid turnover once removed from their packaging. In the case of
low acid, milk-based products this entails at least daily cleaning
and sterilization of the product dispenser--typically at the
expense of a significant labor investment. Unfortunately, the
investment in labor for the required cleaning operations is not the
only disadvantage of known dispensing systems. The labor intensive
cleaning operation is also faulted for the human introduction of
the very contaminants sought to be avoided. For example, inadequate
cleaning of known dispensing systems by exposed persons has been
repeatedly linked to outbreaks of human listeriosis, which can
cause stillbirths, miscarriages, meningitis, sepsis and the like,
especially in elderly or otherwise immunocompromised hosts.
[0007] With the shortcomings of the prior art clearly in mind, it
is an overriding object of the present invention to improve upon
the prior art by providing a dispensing system wherein an aseptic
product may be delivered as near as possible to the consumer
without introduction of microbial agents, thereby generally
increasing the safety of dispensed food and beverage products. It
is a further object of the present invention to provide such a
system wherein the labor resources required for maintenance are
reduced and the opportunity for human introduction of contaminants
minimized. It is a still further object of the present invention to
provide such a system wherein product waste is minimized, thereby
contributing to increased profits without compromise of the
provided consumer safety features.
SUMMARY OF THE INVENTION
[0008] In accordance with the foregoing objects, the present
invention--an aseptic product dispensing system--generally
comprises a sanitary connection assembly interposed in fluid
communication with a substantially conventional aseptic product
source and a substantially conventional product dispenser.
According to the preferred embodiment, the sanitary connection
assembly is provided with an automated cleaning system whereby a
combination of pressurized gas, water and/or sanitizing solution
may be injected into, and thereafter evacuated from, the sanitary
connection assembly.
[0009] A first portion of the sanitary connection assembly remains
in fixed fluid communication with the product dispenser while a
second portion of the sanitary connection assembly, which may be
selectively isolated from the first portion according to the
actuation of an interposed valve, is releasably connected to the
aseptic product source. According to the preferred method of the
present invention, the aseptic product source is connected to the
second portion of the sanitary connection assembly while the
interposed valve is closed to isolate the first portion of the
sanitary connection assembly. Once the aseptic product source is
connected, the second portion of the sanitary connection assembly
is flushed with the automated cleaning system, whereafter the
interposed valve may be opened to allow the sanitary communication
of aseptic product into the product dispenser.
[0010] The automated cleaning system of the aseptic product
dispensing system generally includes a source of pressurized
sanitizing solution, a source of pressurized flushing fluid and a
source of pressurized gas, each in selective fluid communication
with the flushing inlet of the sanitary connection assembly through
interposed flow-control valves. An integrated microprocessor based
controller of conventional implementation is provided for operative
control of the valves of the sanitary connection assembly and
automated cleaning system. This controller generally interfaces
with a plurality of sensors or transducers and a plurality of valve
controllers to detect the presence or absence of product in the
various stages of the dispensing system and to monitor the valve
positions and component connections. The controller then controls
the valve positions and fluid flows in response to the sensed or
monitored inputs.
[0011] Finally, many other features, objects and advantages of the
present invention will be apparent to those of ordinary skill in
the relevant arts, especially in light of the foregoing discussions
and the following drawings and exemplary detailed description and
the claims drawn thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Although the scope of the present invention is much broader
than any particular embodiment, a detailed description of the
preferred embodiment follows together with illustrative figures,
wherein like reference numerals refer to like components, and
wherein:
[0013] FIG. 1 shows, in schematic block diagram, the preferred
embodiment of the aseptic product dispensing system of the present
invention;
[0014] FIG. 2 shows, in schematic block diagram, the sanitary
connection assembly and automated cleaning system of the aseptic
product dispensing system of FIG. 1;
[0015] FIG. 3 shows, in schematic block diagram, an alternative
embodiment of the product dispensing system of FIG. 1, wherein
certain components are redundantly provided;
[0016] FIG. 4 shows, in flow chart, the preferred embodiment of the
general control scheme of the aseptic product dispensing
system;
[0017] FIG. 5 shows, in flow chart, the product unload routine
corresponding to the general control scheme of FIG. 4;
[0018] FIG. 6 shows, in flow chart, the product load routine
corresponding to the general control scheme of FIG. 4;
[0019] FIG. 7 shows, in flow chart, the dispenser fill routine
corresponding to the general control scheme of FIG. 4;
[0020] FIG. 8 shows, in flow chart, the product dispense routine
corresponding to the general control scheme of FIG. 4; and
[0021] FIG. 9 shows, in flow chart, the full system cleaning and
sanitizing routine corresponding to the general control scheme of
FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Although those of ordinary skill in the art will readily
recognize many alternative embodiments, especially in light of the
illustrations provided herein, this detailed description is
exemplary of the preferred embodiment of the present invention, the
scope of which is limited only by the claims drawn hereto.
[0023] Referring generally to the Figures and, in particular, to
FIGS. 1 and 2, the aseptic product dispensing system 10 is shown to
generally include a sanitary connection assembly 11 interposed in
fluid communication with a substantially conventional aseptic
product source 12 and a substantially conventional product
dispenser 13. According to the preferred embodiment of the aseptic
product dispensing system 10, the sanitary connection assembly 11
is provided with an automated cleaning system 14 whereby a
combination of pressurized gas 15, flushing fluid 16, such as for
example water, and/or sanitizing solution 17 may be injected into,
and thereafter evacuated from, the sanitary connection assembly
11.
[0024] In the preferred embodiment of the aseptic product
dispensing system 10, a first portion 18 of the sanitary connection
assembly 11 remains in fixed fluid communication with the product
dispenser 13. A second portion 19 of the sanitary connection
assembly 11, which may be selectively isolated from the first
portion 18 according to the actuation of an interposed valve 20, is
releasably connected to the aseptic product source 12. According to
the preferred method, the aseptic product source 12 is connected to
the second portion 19 of the sanitary connection assembly 1 1 while
the interposed valve 20 is closed to isolate the first portion 18
of the sanitary connection assembly 11. Once the aseptic product
source 12 is connected, the second portion 19 of the sanitary
connection assembly 11 is flushed with the automated cleaning
system 14, whereafter the interposed valve 20 may be opened to
allow the sanitary communication of aseptic product 21 into the
product dispenser 13. These and other aspects of the present
invention 10 will be more fully understood after detailed
description of each of the foregoing components and steps, which
now follows.
[0025] Referring now to FIG. 2 in particular, the preferred
embodiment of the sanitary connection assembly 11 is detailed. In
general, the sanitary connection assembly 11 comprises a cavernous
body 22 and a hose connector 23, which together define a first
cavity portion 24 and a second cavity portion 25. The body 22 may
be constructed of any suitable material as now utilized in the
manufacture of food product dispensing items, such as hardened
plastic or stainless steel. Although a unitary construction is
preferred for simplification of the assembly process, those of
ordinary skill in the art will recognize that many other
substantially equivalent structures may be substituted. Finally,
the body 22 is preferably of a substantially cylindrical shape for
simplification of the interface with the hose connector 23. Those
of ordinary skill in the art, however, will recognize that other
general forms may be substituted within the spirit of the invention
with only corresponding loss of the connection advantages.
[0026] As also shown in FIG. 2, the cavernous body 22 defines a
first cavity portion 24 for the passage of product 21 en route the
product dispenser 13. This first cavity 24 terminates in a product
outlet 26 for connection with, and fluid communication of product
21 to, the product dispenser 13. As shown, the product outlet 26 is
preferably barbed 28 to facilitate the secure friction fit
attachment of a tube or hose 29 to product dispenser 13 or a freeze
chamber 27 therein. Because it is important that the entire system
10 be airtight and contaminant free, hose clamps or luer-type locks
may also be utilized at places like the product outlet 26 to
further ensure the system's integrity.
[0027] The first cavity portion 24 receives product 21 from a
second cavity portion 25, detailed further herein, through a
product port 30 opposite the product outlet 26. Flow through the
product port 30 is regulated by a poppet-type product flow-control
valve 20. Although those of ordinary skill in the art will
recognize many alternative embodiments, in the preferred embodiment
this valve 20 is dependently supported upon a mounting projection
31 extending from the interior wall 32 of the body 22 near the
product outlet 26. The valve 20 generally comprises a polymeric
gasket 33 supported by a valve carrier 34, biased against and
seated over the product port 30 by a biasing spring 35 disposed in
the longitudinal axis of the valve's poppet action. Although in the
preferred embodiment the valve 20 is actuated upon reaching a
predetermined threshold pressure in the second cavity 25, the valve
20 may be actuated by any known means, including a cam mechanism or
solenoid. In the case of external activation, however, an
electrically controllable means is preferred as will be more
apparent further herein. Finally, the biasing spring 35 and any
actuation hardware are enclosed in, and protected by, a polymeric
boot 36, which may be extended or compressed along the longitudinal
axis of the valve 20. These and other aspects of the flow-control
valve's operation will be even better understood upon discussion of
the present invention's operation, further herein.
[0028] The second cavity portion 25 of the sanitary connection
assembly 11 is formed through the union of a specially adapted hose
connector 23 and a receptacle 37 formed on the end of the cavernous
body 22. The receptacle 37 is cylindrically shaped for easy
connection of the hose connector 23 as detailed further herein. In
the preferred embodiment, the receptacle comprises a central
product aperture 38 oriented along the longitudinal axis of the
body 22 and directed from the product hose 39, detailed further
herein, toward the product port 30 to the first cavity portion 24
and an annular flushing cavity 89 about the central product
aperture 38. As will also be better understood further herein, this
annular flushing cavity 89 is specifically adapted to facilitate
sterilization of the connector assembly 11 after connection of the
hose connector 23 and prior to product 21 flow. A cannular
projection 40 is provided at the tip of the receptacle 37 for
piercing a sanitary protective cover of the hose connector 23 and
an O-ring 41 is provided about the circumference of the receptacle
37 to facilitate sealing engagement of the hose connector 23. In
this manner, the hose connector 23 may be press fit onto the
receptacle 37, with minimum opportunity for human contamination of
the interior spaces of the hose connector 23.
[0029] Finally, a flushing inlet 42 and a drain port 43 are each
provided in fluid communication with the annular flushing cavity 89
and, therethrough, with the central product aperture 38. As with
the product outlet 26, the flushing inlet 42 and drain port 43 are
preferably provided with exterior barbs 44, 45 and may also be
adapted for use with hose clamps or luer-type locks to ensure
system integrity. As will be better understood further herein, the
flushing inlet 42 is fixedly attached to an automated cleaning
system 14, which according to the preferred method of the present
invention injects sanitizing solution 17, flushing fluid 16 and/or
gas 15 into the sanitary connection assembly 11 for the automated
cleaning thereof. The injected cleaning product 15, 16, 17 is then
evacuated through the drain port 43, which is provided with a pinch
shut-off valve 46 to allow flow therethrough only during the
cleaning operation thereby preventing the entry of
contaminants.
[0030] Still referring to FIG. 2, the hose connector 23 of the
sanitary connection assembly 11 is now detailed. As shown in the
Figure, the hose connector 23 is preferably shaped for abutting
engagement with the receptacle 37 of the cavernous body 22. In
particular, the hose connector 23 is provided with a beveled
central portion 47 that tapers outwardly to a radial shoulder 48.
The beveled central portion 47 thereby encompasses the cannular tip
40 of the receptacle 37. The circular edge 49 of the cap is adapted
to fit tightly about the outer surface of the receptacle 37 and to
engage the O-ring 41 thereabout in a sealed friction fit. As can be
seen in the Figure, the union of the hose connector 23 with the
receptacle 37 forms the interior aperture 38 from the product hose
39 to the product port 30, but also leaves a circumferential
channel 50 about the exterior of the cannular tip 40 and into the
annular flushing cavity 89. As will now be apparent to those of
ordinary skill in the art, this channel 50 enables sanitizing of
the face of the receptacle 37 after application of the hose
connector 23 but prior to product 21 flow.
[0031] As also shown in FIG. 2, a product hose 39 from the
substantially conventional aseptic product package 51 is fixedly
attached to the specially adapted hose connector 23 by friction fit
over a barbed projection 52. The product hose 39 is preferably
retained securely in place on the hose connector 23 with a ferrule
53, which preferably comprises an outwardly projecting flange 54
for use in securing the hose connector 23 to the receptacle 37 as
will be better understood further herein. As will be understood by
those of ordinary skill in the art, however, the product hose 39
could be integrally manufactured with the hose connector 23.
[0032] A check valve 55 for preventing back flow of product 21
and/or contaminants into the product hose 39 is formed in the
connector's aperture 56 by a polymeric ball 57 pressed into a
spherical socket 58 by a biasing spring 59. In this manner, product
21 may only flow when forced through the hose 39 to displace the
ball 57 against the spring 59 and away from the spherical socket
58. Upon cessation of forced flow, the biasing spring 59
immediately and firmly presses the ball 57 back into the spherical
socket 58, preventing any back flow of product 21 and/or
contaminants.
[0033] To further minimize any chance for the introduction of
contaminants into the aseptic product dispensing system 10, the
specially adapted hose connector 23 is also preferably provided
with exterior threading 60 to allow placement of a cap. Such a cap
is utilized to keep the face of the hose connector 23 clean during
storage or transportation of the aseptic product source 12 and is
preferably only removed just prior to loading of the product 12
into the aseptic product dispensing system 10. In addition, the
face of the hose connector 23 is manufactured with a perforable
cover, such as those well known for use in safety sealing of
commercially available medicines, food products and the like. At
the time of product loading, the cannular tip 40 of the receptacle
37 is used to puncture the perforable cover, thereby establishing
fluid communication with the interior of the hose connector 23 with
absolute minimum human contact.
[0034] Referring now to FIGS. 1 and 2 together, the automated
cleaning system 14 of the aseptic product dispensing system 10 is
shown to generally comprise a source 61 of pressurized sanitizing
solution 17, a source 62 of pressurized flushing fluid 16 and a
source 63 of pressurized gas 15, each in selective fluid
communication with the flushing inlet 42 of the sanitary connection
assembly 11 through interposed flow-control valves 64, 65, 66. Each
source 61, 62, 63 is further isolated one from another as well as
from the connection assembly 11 via a plurality of interposed check
valves 67, 68, 69, 70, which may comprise ball valves or any other
substantial equivalent as well known in the art. Although in the
preferred embodiment the pressurized gas 15 is chosen to be carbon
dioxide, those of ordinary skill in the art will recognize that
many substantially equivalent gases may be substituted, the primary
considerations in the choice being the desirability to use a gas 15
that is generally non-supportive of microbial growth but also not
harmful to humans.
[0035] In the preferred embodiment of the aseptic product
dispensing system 10, the flow-control valves 64, 65, 66 of the
automated cleaning system comprise solenoid valves, which are easy
to control in an automated system. Those of ordinary skill in the
art, however, will recognize that other types of valves may be
equivalently substituted with only corresponding sacrifice in
controllability while remaining well within the scope of the
present invention. For example, although the preferred embodiment
comprises a fully automated control and monitoring system, detailed
further herein, many aspects of the present invention may be
appreciated without full implementation of such a system. In one
such alternative embodiment, the cleaning operation may be manually
controlled wherein the flow-control valves 64, 65, 66 are manually
opened and closed. In any case, it is critical only that the
pressurized flows from the three sources 61, 62, 63 be selectively
controllable through some means.
[0036] While the depiction of FIG. 2 indicates that the check valve
70 between the automated cleaning system 14 and the sanitary
connection assembly 11 may be placed within the tubing or hosing 71
running between the automated cleaning system 14 and the flushing
inlet 42, it is to be understood that this valve 70 may preferably
be situated elsewhere. As will be better understood further herein,
a positive pressure exists within the second cavity portion 25 of
the cavernous body 22 during operation of the aseptic product
dispensing system 10. As a result, placement of the check valve 70
within flushing inlet 42 would serve to virtually eliminate any
possibility of contamination in the event of a hose failure or
inadvertent disconnection during use. Upon complete review of the
present teachings, however, these and other options for placement
of such safety features, including the placement of redundant
components, will be appreciated by those of ordinary skill in the
art.
[0037] An integrated microprocessor based controller 72 of
conventional implementation, as well known to those of ordinary
skill in the art, is provided for operative control of the valves
of the sanitary connection assembly 11 and automated cleaning
system 14. Although the complete operation of the controller 72
will be better understood further herein, the controller 72
generally interfaces with a plurality of sensors or transducers and
a plurality of valve controllers to detect the presence or absence
of product 21 in the various stages of the aseptic product
dispensing system 10 and to monitor the valve positions and
component connections. The controller 72 then controls the valve
positions and fluid flows in response to the sensed or monitored
inputs.
[0038] Referring now more particularly to FIG. 1, the placement of
the sanitary connection assembly 11 within the aseptic product
dispensing system 10 is detailed. Although the aseptic product
source 12 is substantially conventional, the source 12 is modified
for the present invention to comprise an elongate, compressible
product hose 39 terminating in the specially adapted hose connector
23 as previously described. The aseptic product dispensing system
10 comprises a pump 73 for forcing product 21 from the product
package 51 through the hose connector 23 and into the sanitary
connection system 11 and freeze chamber 27 of the product dispenser
13. As the conventionally known aseptic products 12 are typically
provided with a flexible packaging 5 1, means 74 for applying
pressure directly to the packaging 51 is also preferred.
[0039] According to the preferred embodiment, the pump 73 is a
peristaltic pump, which, as shown, gently squeezes the product 21
through the product hose 39 without emulsification or other
agitation. Additionally, the peristaltic pump 73 provides a type of
check valve, wherein flow is strictly limited to one direction.
Those of ordinary skill in the art will, of course, recognize that
other pumps may be substituted. For example, a pneumatically
operated double-diaphragm pump or even a centrifugal pump could be
used.
[0040] Finally, a pinch shut-off valve 75 is provided for
connection about the product hose 39 prior to connection of the
hose connector 23 to the sanitary connection assembly 11. This
provides an extra measure of security against inadvertent
contamination in the unlikely event that the check valve 55 within
the hose connector 23 should be defective or for some reason fail
to properly operate. As will be apparent to those of ordinary skill
in the art, the shut-off valve 75 as well as the pump 73 must be
adapted to allow insertion of the product hose 39 with the hose
connector 23 in place. The necessary modifications to the readily
available components are, however, well within the reach of one of
ordinary skill in the art.
[0041] As shown in the Figure, the aseptic product dispensing
system 10 also comprises an automated engagement and connection
system 76 for securing the hose connector 23 to the cavernous body
22. In particular, the cavernous body 22 is placed upon slide rails
77 or other substantially equivalent means for effecting a
controlled longitudinal translation. In use, the hose connector 23
is snapped laterally into slots, which according to the preferred
embodiment conform to the ferrule 53 of the hose connector,
whereafter the cavernous body 22 is longitudinally translated to
force engagement of the receptacle 37 with the hose connector 23.
As depicted, a pressurized air source 78 may be utilized to effect
the longitudinal translation of the cavernous body 22.
[0042] Those of ordinary skill in the art, however, will recognize
many alternative embodiments for the engagement of the hose
connector 23 and cavernous body 22 for the secure formation of the
sanitary connection assembly 11. For example, simple friction fit
connection or manual connection with snaps, brackets or other
connectors may be implemented. The automated system 76 described is
presently preferred, however, notwithstanding the greater
complexity, as it provides opportunity for electronic feedback of
the connection status and serves to ensure a very secure connection
23 of the hose connector to the cavernous body 22.
[0043] Those of ordinary skill in the art will also recognize that
many alternative embodiments may be formulated for the automated
engagement system 76. For example, but not by way of limitation,
the cavernous body 22 may be translated by a solenoid, on a worm
gear or by a rack and pinion system. Likewise, the cavernous body
22 may be maintained in place while the hose connector 23 is
longitudinally translated into secure engagement with the
receptacle 37. In any case, all such implementations should be
within the reach of those of ordinary skill in the art upon review
of the teachings herein.
[0044] The product dispenser 13 is substantially similar to that
well known to those of ordinary skill in the art. In the preferred
embodiment, however, the product dispenser 13 is isolated from the
sanitary connection assembly 11 through a check valve 79, thereby
further ensuring the aseptic integrity of the system 10. A vent 80,
comprising therein a selectively actuatable valve, is also provided
to allow the one-way escape of air or other gas during the filling
of the product dispenser 13. Various controls and indicators are
preferably located on the front panel 81 of the dispenser 13, the
function of which will be apparent upon review of the following
discussions detailing the preferred operation of the aseptic
product dispensing system 10.
[0045] Referring now to FIG. 4, the general control scheme 82 for
the preferred embodiment is now detailed. Upon start up, the
controller 72 enters an interrupt style control loop 83 wherein the
quantity status of the product source is monitored and dispensing,
cleaning and filling operations may be initiated. Although those of
ordinary skill in the art will recognize the existence of virtually
endless implementations for such a control scheme 82, or a
substantial equivalent thereof, the presently preferred embodiment
in particular begins the loop 83 by ascertaining whether the
product source has been depleted 84. This may be done, for example,
by polling a sensor 85 in the line from the sanitary connection
assembly 11 to the product dispenser 13 or, equivalently, in
another appropriate part of the aseptic product dispensing system
10. So long as no user input has been given and the product 21
supply remains positive, the controller 72 simply loops through the
overall scheme 82 checking in turn for a user input to initiate the
product dispensing operation 86, a timing trigger (or user input)
to initiate a full system cleaning operation 87 or a sensed product
low condition (or user input) to initiate a dispenser filling
operation 88. The loop then repeats.
[0046] In the event that the product 21 supply becomes depleted or
a user input directs the initiation of some operation, the loop 83
is interrupted for completion of an appropriate course of action.
For example, if the product 21 source becomes depleted the
controller 72 signals 90 the empty state through the dispensing
system's warning system 91 and then begins the product unload
routine 92, as depicted in FIG. 5 and detailed further herein.
Likewise, in the event that a user input is detected for initiation
of one of the system's other operations the loop 83 is interrupted
for completion of that operation. In particular, if the user wishes
to dispense product 21 the user's desire will be communicated
through the dispenser actuator 93, comprising an electronic switch
therein, and detected by the control loop as the loop 83 polls for
the initiation of a product dispense operation 86. Upon detection
of this state, the controller begins the dispense operation 94, as
depicted in FIG. 8 and detailed further herein. When the controller
72 detects that the predetermined time for cleaning has arrived (or
that the user wishes to initiate a full system cleaning operation),
a signal is detected by the control loop 83 and the full system
sanitizing routine 95 is initiated, as depicted in FIG. 9 and
detailed further herein. Finally, communication from an appropriate
sensor that the product level is low (or receipt of a signal
indicating the user's desire to fill the dispenser) initiates the
dispenser fill routine 96, as depicted in FIG. 7 and detailed
further herein. Each of these operations 92, 94, 95, 96 is now
detailed in turn.
[0047] Referring now to FIG. 5 in particular, the product unload
routine 92 of the preferred embodiment is now detailed. As depicted
in the Figure, the routine 92 begins by determining 97 whether the
user has indicated, preferably through activation of a push-button
switch 98 at the system's front panel 82, a desire to unload the
spent product packaging 51. If so, the controller 72 first directs
99 the opening of the pinch shut-off valve 46 in the drain hose 100
from the drain port 43 of the sanitary connection assembly 11. In
order to prevent damage to the system's check valves 55 or the
creation of forced back flows therethrough and the resulting
possibility of contamination, the controller 72 then checks 101 to
ensure that the pinch shut-off valve 46 is open. If not, the entire
dispensing system 10 is shut down 102, preferably alerting the user
to the trouble via the warning system 91. A service technician then
corrects the malfunction and resets 103 the aseptic product
dispensing system 10, whereafter the process 92 resumes with a
determination 97 of whether the user still desires to unload the
spent product 51. Provided the shut-off valve 46 did open, however,
the controller 72 goes on to perform a flushing sequence prior to
disengagement of the hose connector 23 from the cavernous body
22.
[0048] By opening the appropriate flow-control valves 65, 66,
pressurized sanitizing solution 17 and/or pressurized flushing
fluid 16 are flowed 104 through the flushing inlet 42 into the
annular flushing cavity 89 and central product aperture 38 and then
evacuated through the drain port 43 to the drain hose 100. Upon
initiation 104 of the fluid flow, the system 72 preferably makes a
check 105 to verify actual flow, utilizing sensors or the like
known to those of ordinary skill in the art, thereby ensuring that
the receptacle 37 and hose connector 23 regions of the sanitary
connection assembly 11 will be cleansed of product 21 prior to
disengagement. In the event that fluid 16, 17 is not flowing, the
system shuts down 102 as previously described and preferably alerts
the user to the trouble via the warning system 91. Assuming the
flushing fluid 16, 17 is actually flowing, however, the controller
72 then terminates 106 flow of the flushing fluid 16, 17,
preferably after lapse of some predetermined time, by closing those
flow-control valves 65, 66 previously opened. The controller 72
checks 107 to ensure that the flushing fluid 16, 17 has stopped,
again going through a shut down 102 if not, and then by opening the
appropriate flow-control valve 64 initiates 108 flow of pressurized
gas 15 for evacuation of the flushing fluid 16, 17 from the
sanitary connection assembly 11. The controller 72 checks 109 to
ensure that gas 15 is actually flowing, again by use of sensors
well known to those of ordinary skill in the art, and then, after a
predetermined delay, substantially simultaneously terminates 110
flow of the pressurized gas by closing the previously opened
flow-control valve 64 and closes the pinch shut-off valve 46 in
about the drain hose 100. As a final check, the controller 72 polls
111 an appropriate sensor to ensure the gas flow has stopped and
the pinch shut-off valve 46 has closed. Assuming as much, the
flushing operation terminates.
[0049] Upon termination of the flushing operation, the automated
engagement and connection system 76 disengages 112 the hose
connector 23 from the receptacle 37 of the sanitary connection
system 11. A check 113 is performed to ensure that the hose
connector 23 and receptacle 37 did disengage, whereafter the hose
connector 23 is free for removal from the sanitary connection
assembly 11. The user, who is preferably notified of this status
via an indicator on the front panel 81 of the product dispenser 13,
is then able to remove the product hose 39 from the pinch shut-off
valve 75 and the peristaltic pump 73 and the aseptic product
package 51 from its container 114. The product unload routine 92
then terminates, the controller 72 looking next to an input
indicating the user's desire to load a new aseptic product package
51 into the aseptic product dispensing system 10.
[0050] At this point, see FIG. 6, the controller 72 will poll 115
the load switch 116 on the product dispenser's front panel 81 but,
because the user has not had enough time to place a new product
package 51 and product hose 39 into the aseptic product dispensing
system 10, will probably not find a load indication. At this point,
the control loop 83 depicted in FIG. 4 will resume, continuing to
signal 90 that the product source 12 is empty and giving the user
the opportunity to place a new aseptic product package 51 into the
container 114 and to feed the product hose 39 through the
peristaltic pump 73 and pinch shut-off valve 75. After the user
places the new hose connector 23 into the provided slots and
presses the load button 116 on the front panel 81 of the product
dispenser 13, the controller 72 detects 115 the load activated
indication and continues with the product load routine 117, as
depicted in FIG. 6.
[0051] Referring now to FIG. 6, when the controller 72 detects 115
a load activated indication the automated engagement and connection
system 76 engages 118 the receptacle 37 of the sanitary connection
assembly 11 into the new hose connector 23. A check 119 is then
made to ensure that a secure engagement has taken place. If not,
the aseptic product dispensing system 10 is shut down 120,
preferably alerting the user to the trouble via the warning system
91. A service technician then corrects the malfunction and reset
121 the aseptic product dispensing system 10, whereafter the
controller 72 looks again 115 for an indication that the user
desires to run the product load routine 117. Assuming that a secure
engagement has taken place, however, the controller 72 next
executes an automated cleaning and sanitizing of the sanitary
connection assembly 11.
[0052] As also shown in FIG. 6, the automated cleaning routine
begins with the controller 72 opening 122 the pinch shut-off valve
46 in the drain hose 100 from the drain port 43 of the sanitary
connection assembly 11. As with the product unload routine 92, a
check 123 is made to ensure that the pinch shut-off valve 46 is
open prior to flowing 124 pressurized sanitizing fluid 17. Assuming
that the pinch shut-off valve 46 did properly open, the controller
72 then initiates 124 the flow of pressurized sanitizing fluid 17
by actuating the flow-control valve 65 interposed in the line
between the sanitizing fluid source 61 and the flushing inlet 42 of
the sanitary connection assembly 11. Again, a check 125 is made to
ensure actual flow of pressurized sanitizing fluid 17.
[0053] Sanitizing fluid 17 then enters the annular flushing cavity
89 and central product aperture 38 through the flushing inlet 42.
Because the flushing fluid 17 is preferably under fair pressure, it
fully floods the second cavity portion 25 of the sanitary
connection assembly 11 killing and/or removing any contaminants as
may have entered during the product change. After a predetermined
time, the pinch shut-off valve 46 and the flow-control valve 65 are
substantially simultaneously controlled 126 to close the drain port
42 and stop the flow of sanitizing fluid 17, thereby entering a
soaking cycle. As before, a check 127 is performed to ensure the
valves 46, 65 did in fact operate as desired. After another
predetermined delay, the drain port 42 is again opened 129 to allow
evacuation of the sanitizing solution 17 although, in an
alternative embodiment, a preset number of flushing and soaking
cycles 128 may be desired prior to evacuation of the chamber
25.
[0054] After checking 130 to ensure that the drain port 42 is
properly open, the controller 72 flows pressurized gas 15 into the
second cavity 25 by actuating 131 the flow-control valve 64
interposed in the line between the gas source 63 and the flushing
inlet 42. Checking 132 first to ensure proper valve 64 positioning,
the controller 72 then allows the pressurized gas 15 to flow for a
desired time period. The drain port 42 is then closed 133
simultaneously with the cessation of gas flow and valve positions
are checked 134, concluding the product load routine 117. The
controller 72 then returns to the control loop 83 depicted in FIG.
4.
[0055] As the controller 72 polls the various switches on the front
panel 81 of the product dispenser 13, one indication as may be
determined is the user's desire to dispense product 21. Upon
detection of this indication, the controller 72 interrupts the
control loop 83 to execute the product dispense routine 94, as
depicted in FIG. 8. This routine 94 begins with the opening 135 of
the product dispensing valve 136. The valve 136 remains open so
long as the user maintains a desire 137 to dispense product 21;
whereafter the product dispensing valve 136 is closed 138. Prior to
returning to the control loop 83 of FIG. 4, a check 139 is made to
ensure that the dispensing valve 136 did close. If not, the aseptic
product dispensing system 10 shuts down 140 as previously
described, preferably alerting the user to the trouble via the
warning system 91. If so, however, the dispensing routine 94
terminates and the control loop 83 resumes.
[0056] Another indication as may be polled by the control loop 83
is the arrival of the predetermined time for full cleaning of the
aseptic product dispensing system 10 (or the user's desire to
initiate a full system cleaning) 87. In the full system cleaning or
sanitizing routine 95, as depicted in FIG. 9, the automated
cleaning system 14 is utilized to sanitize not only the sanitary
connection assembly 11 but also the product dispenser 13. The user
may elect to perform this operation at any time, but, to ensure
minimal product 21 waste, it is preferred that the user perform
this operation only after receiving an indication that the product
dispenser 13 is empty. The full system cleaning routine 95 will
also preferably always be performed after a predetermined safety
time has elapsed or upon the arrival of a predetermined hour.
[0057] The sanitizing routine 95 begins by opening 142 the product
dispensing valve 136 on the front of the product dispenser 13. It
should be noted that while manually operated valves are typically
utilized for product dispensing, it is preferred that an automated,
electrical type valve be used in order to better interface with the
automated cleaning feature now described. In any case, after
checking 143 to ensure that the product dispensing valve 136 did
properly open the controller 72 initiates 144 the flow of
pressurized flushing fluid 16 by actuating the appropriate
flow-control valve 66 in the line between the flushing fluid source
62 and the flushing inlet 42. As in the previously described
operations, a check 145 is made to ensure actual flow of
pressurized flushing fluid 16.
[0058] Although those of ordinary skill in the art will recognize
that the controller 72 could then open the product flow-control
valve 20 between the first 24 and second 25 cavities of the
sanitary connection assembly 11, the preferred embodiment utilizes
the pressure of the flushing 16 or sanitizing 17 solution to push
the valve 20 against the biasing spring 35 and off its seat 146,
thereby allowing flow from the second cavity 25 to the first cavity
24. In this manner, the possibility for back flow to the second
cavity 25 of any contaminant as may be present in the first cavity
24 is greatly reduced. Those of ordinary skill in the art will
recognize, therefore, that it is necessary to design the valves 20,
46 of the system such that the product flow-control valve 20 is
displaced by the pressure of the automated cleaning system 14 when
and only when the drain port 43 is closed.
[0059] After a predetermined time, the flow of pressurized flushing
fluid 16 is terminated 147 and a flow of pressurized sanitizing
fluid 17 is established 148 in its place. As with each previous
step in the control scheme 82, a check 149, 150 is performed after
each valve operation to ensure the desired state is achieved. After
another predetermined time has elapsed, the flow of sanitizing
fluid 17 is stopped 151 simultaneously with the closing of the
product dispensing valve 136, the controller 72 again polling 152
the appropriate sensors to ensure the desired valve states. As was
the case in the product load routine 117 of FIG. 6, the
simultaneous valve closings 151 serve to establish a soak cycle for
the product dispenser 13. At the timed conclusion of this soak
cycle, the dispenser valve 136 is opened 153 and checked 154.
Similar to the product load routine 117, those of ordinary skill in
the art will recognize that in at least an alternative embodiment
the controller 72 may be programmed to repeat 155 the flow of
sanitizing solution 17 until a preset number of cycles has been
achieved. In any case, after the one or more desired soak cycles,
the controller 72 flows 156 pressurized gas 15 into the sanitary
connection assembly 11 and product dispenser 13 and checks 157 to
ensure proper gas flow. After the pressurized gas 15 displaces the
flushing fluid 16 and/or sanitizing solution 17 through the product
dispensing valve 136 the controller 72 substantially simultaneously
closes 158 the product dispenser valve 136 and stops the
pressurized gas flow, checking 159 the appropriate valves and lines
to ensure both.
[0060] The aseptic product dispensing system 10 now stands ready
for filling, completely cleaned and sanitized and with a positive
internal gas pressure serving to prevent the inadvertent
introduction of contaminants. At this point, the controller 72
repeatedly polls 160 the appropriate switch on the front panel 81
of the product dispenser 13 to determine whether the user desires
to restart the system. If so, the system 10 is restarted 161
without necessity for software or hardware initialization. Provided
that the system 10 properly restarts 162, the product fill routine
96 as depicted in FIG. 7 is then executed. Of course, those of
ordinary skill in the art will recognize that instead of restarting
161 the system the user may decide at this point to power off the
aseptic product dispensing system 10. In the preferred embodiment,
however, the aseptic product dispensing system 10 will
automatically restart 161 at the arrival of a predetermined hour
such as, for example, just before store opening time.
[0061] The dispenser fill routine 92, depicted in FIG. 7, is
generally entered either directly following a system restart 161 at
the termination of the full system sanitizing routine 95, at the
arrival of a predetermined time or upon receipt of a user input. In
any case, the product fill routine 92 begins with the controller's
opening 163 of the vent valve 80 on the product dispenser 13. As
with all previous valve operations, the controller 72 performs a
check 164 to determine that the vent valve 80 did open, thereby
ensuring a channel for the displacement of the gas 15 within the
product dispenser 13 by the introduced product 21. As with each
previous routine, a negative indication at any valve or flow check
is responded to by a system shut down 165 and notification through
the warning system 91. A service technician then corrects the
malfunction and resets 166 the aseptic product dispensing system
10.
[0062] In order to fill the product dispenser 13, the controller 72
then activates 167 the peristaltic pump 73 to move product 21 from
the aseptic product source 12, past the check valve 58 in the hose
connector 23 and into the second cavity 25 of the sanitary
connection assembly 11. At this point the pressure of the product
21 will build to the point of displacing the product flow-control
valve 20 against the biasing spring 35 and off its seat 146,
thereby allowing flow from the second cavity 25 to the first cavity
24. A check 168 is made to ensure that product 21 is flowing from
the sanitary connection assembly 11 into the product dispenser 13
or a freeze chamber 27 therein, whereafter flow is allowed to
continue until the desired level is reached. Upon reaching the
desired product level 169, the product flow is terminated 170
substantially simultaneously with the closing of the vent valve 80.
Upon checking 171 to ensure the flow has been terminated and the
vent valve 80 has been closed, the dispenser fill routine 96
terminates by returning to the control loop 83 of FIG. 4.
[0063] While the foregoing description is exemplary of the
preferred embodiment of the present invention, those of ordinary
skill in the relevant arts will recognize the many variations,
alterations, modifications, substitutions and the like as are
readily possible, especially in light of this description and the
accompanying drawings. For example, those of ordinary skill in the
art will recognize that virtually unlimited control schemes 82 may
be implemented to carry out the concepts of the present invention.
Likewise, those of ordinary skill in the art will also recognize
that virtually unlimited combinations of various valves, lines and
sensors may be utilized to embody the present invention. Finally,
those of ordinary skill in the art will recognize that the present
invention may be carried out substantially as described or may be
implemented with redundancy in its various parts.
[0064] For example, as shown in FIG. 3, the aseptic product
dispensing system 10 may be implemented with a redundant product
source 172, peristaltic pump 173, shut-off valve 174 and sanitary
connection assembly 175. As depicted 176 in the dashed lines of
FIG. 4, this alternative embodiment may be utilized as a secondary
product source for filling a single chamber of the product
dispenser. In this case, the product sources may be consumed
alternatively 177, thereby making product substantially
continuously available so long as the user changes the empty source
while the full source is in use.
[0065] In yet another alternative, the duplicated portions 172,
173, 174, 175 of the system may be provided for purposes of variety
only. In this case, the aseptic product dispensing system 10 shares
some resources, such as the pressurized fluids 16, 17 and gases 15
and the controller hardware 72, while providing separate product
sources 12, 172 for supply of separate chambers in the product
dispenser 13. In any case, because the scope of the present
invention is much broader than any particular embodiment, the
foregoing detailed description should not be construed as a
limitation of the scope of the present invention, which is limited
only by the claims drawn hereto.
* * * * *