U.S. patent application number 11/012784 was filed with the patent office on 2005-05-12 for apparatus for aseptic packaging.
Invention is credited to Taggart, Thomas D..
Application Number | 20050097863 11/012784 |
Document ID | / |
Family ID | 26816312 |
Filed Date | 2005-05-12 |
United States Patent
Application |
20050097863 |
Kind Code |
A1 |
Taggart, Thomas D. |
May 12, 2005 |
Apparatus for aseptic packaging
Abstract
A method and apparatus for providing aseptically processed low
acid products in a container having a small opening, such as a
glass or plastic bottle or jar, at a high output processing
speed.
Inventors: |
Taggart, Thomas D.; (South
Wales, NY) |
Correspondence
Address: |
ARLEN L. OLSEN
SCHMEISER, OLSEN & WATTS
3 LEAR JET LANE
SUITE 201
LATHAM
NY
12110
US
|
Family ID: |
26816312 |
Appl. No.: |
11/012784 |
Filed: |
December 15, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11012784 |
Dec 15, 2004 |
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09871078 |
May 31, 2001 |
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09871078 |
May 31, 2001 |
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09306552 |
May 6, 1999 |
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6536188 |
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60118404 |
Feb 2, 1999 |
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Current U.S.
Class: |
53/167 ;
53/282 |
Current CPC
Class: |
B65B 55/10 20130101;
B67C 7/0033 20130101; B67C 7/0073 20130101 |
Class at
Publication: |
053/167 ;
053/282 |
International
Class: |
B65B 055/00 |
Claims
1-21. (canceled)
22. A device for automatically aseptically bottling aseptically
sterilized foodstuffs comprising: means for providing a plurality
of bottles; means for aseptically disinfecting the bottles at a
rate greater than 100 bottles per minute wherein the means for
aseptically disinfecting the bottles further includes means for
disinfecting an interior of the bottles with a hot atomized
hydrogen peroxide further wherein said plurality of bottles are in
an upright position; and means for aseptically filling the bottles
with aseptically sterilized foodstuffs.
23. An aseptic processing apparatus for aseptically bottling
aseptically sterilized foodstuffs comprising: a sterile tunnel for
surrounding a plurality of bottles with pressurized sterile air; a
conveying apparatus for moving the plurality of bottles through the
sterile tunnel; a bottle infeed, sterilization and conveying
apparatus for sterilizing an exterior surface of each bottle and
for feeding the sterilized bottles into the sterile tunnel; an
interior bottle sterilization apparatus for applying a sterilant to
an interior surface of each bottle; an activation and drying
apparatus for activating and removing the sterilant from the
interior surface of each bottle; a product filler apparatus for
filling the aseptically sterilized plurality of bottles with the
aseptically sterilized foodstuffs; a lidding apparatus for applying
a sterilized lid to each bottle; and a bottle discharge apparatus
for removing the bottles from the sterile tunnel.
24. The aseptic processing apparatus according to claim 23, wherein
the sterile tunnel further includes a plurality of partitions
forming a plurality of sterilant concentration zones.
25. The aseptic processing apparatus according to claim 23, wherein
each bottle has an opening size to height ratio of less than
one.
26. The aseptic processing apparatus according to claim 23, wherein
the sterilant is hydrogen peroxide.
27. The aseptic processing apparatus according to claim 23, wherein
the sterilant is oxonia.
28. The aseptic processing apparatus according to claim 23, further
including a lid sterilization apparatus.
29. The aseptic processing apparatus according to claim 23, wherein
the plurality of bottles are made from plastic.
30. The aseptic processing apparatus according to claim 29, wherein
the plastic is polyethylene terepthalate.
31. The aseptic processing apparatus according to claim 29, wherein
the plastic is high density polyethylene.
32. The aseptic processing apparatus according to claim 23, further
including a feedback control system for maintaining aseptic
bottling conditions.
33. The aseptic processing apparatus according to claim 23, wherein
the product filling apparatus fills the plurality of bottles at a
rate greater than 360 bottles per minute.
34. The aseptic processing apparatus according to claim 23, wherein
the sterile tunnel encloses the interior bottle sterilization
apparatus, the activation and drying apparatus, the product filler
apparatus, and the lidding apparatus.
35. The device according to claim 22, wherein each bottle has an
opening size to height ratio of less than one.
36. The device according to claim 22, wherein the plurality of
bottles are made from a glass.
37. The device according to claim 22, wherein the plurality of
bottles are made from a plastic.
38. The device according to claim 37, wherein the plastic is
selected from the group: polyethylene terepthatlate and high
density polyehylene.
39. The device according to claim 22, wherein the means for
disinfecting an interior of the bottles includes an application of
the hot hydrogen peroxide spray for about 1 second and an
activation and removal of the hot hydrogen peroxide using hot
aseptically sterilized air for about 24 seconds.
40. The device according to claim 22, further including means for
feedback control for maintaining aseptic bottling conditions.
41. The device according to claim 22, wherein means for aseptically
disinfecting is provided by one of the group: hydrogen peroxide and
oxonia.
42. The device according to claim 22, wherein means for aseptically
disinfecting the bottles includes disinfecting an outside surfaces
of the bottles with hydrogen peroxide.
43. The device according to claim 42, wherein the disinfecting the
outside surfaces includes about 1 second for the application of the
hot hydrogen peroxide spray and about 24 seconds for an activation
and removal of the hot hydrogen peroxide using hot aseptically
sterilized air.
44. The device according to claim 22, wherein the means for
aseptically disinfecting the bottles further comprises: aseptically
disinfecting the bottles at a rate greater than 360 bottles per
minute.
45. The device according to claim 22, wherein the means for
aseptically filling the bottles further comprises: aseptically
filling the bottles at a rate greater than 100 bottles per
minute.
46. A device for automatically aseptically bottling aseptically
sterilized foodstuffs comprising: means for providing a plurality
of bottles; means for aseptically disinfecting the bottles at a
rate greater than 100 bottles per minute; and means for aseptically
filling the bottles with aseptically sterilized foodstuffs, wherein
the aseptically sterilized foodstuffs are sterilized at a level
producing at least a 12 log reduction in Clostridium botulinum.
47. A device for automatically aseptically bottling aseptically
sterilized foodstuffs comprising: means for providing a plurality
of bottles; means for aseptically disinfecting the bottles at a
rate greater than 100 bottles per minute, wherein the aseptically
disinfected bottles are sterilized to a level producing at least a
6 log reduction in spore organisms; and means for aseptically
filling the bottles with aseptically sterilized foodstuffs.
48. A device for automatically aseptically bottling aseptically
sterilized foodstuffs comprising: means for providing a plurality
of bottles; means for aseptically disinfecting the bottles at a
rate greater than 100 bottles per minute, wherein the means for
aseptically disinfecting the bottles further includes means for
disinfecting an interior of the bottles with a hot hydrogen
peroxide spray, further wherein the means for disinfecting an
interior of the bottles includes an application of the hot hydrogen
peroxide spray for about 1 second and an activation and removal of
the hot hydrogen peroxide using hot aseptically sterilized air for
about 24 seconds, wherein the residual level of hydrogen peroxide
is less than 0.5 PPM; and means for aseptically filling the bottles
with aseptically sterilized foodstuffs.
Description
[0001] This application is a divisional of Ser. No. 09/306,552,
filed on May 6, 1999, which is a non-provisional of Ser. No.
60/118,404, filed on Feb. 2, 1999.
FIELD OF THE INVENTION
[0002] The present invention relates generally to systems for the
aseptic packaging of food products. More particularly, the present
invention relates to an aseptic packaging system for the aseptic
packaging of food products in containers such as bottles or
jars.
BACKGROUND OF THE INVENTION
[0003] Sterilized packaging systems in which a sterile food product
is placed and sealed in a container to preserve the product for
later use are well known in the art. Methods of sterilizing
incoming containers, filling the containers with pasteurized
product, and sealing the containers in an aseptic tunnel are also
known.
[0004] Packaged food products can generally be categorized as high
acid products (Ph below 4.5) or low acid products (Ph of 4.5 and
above). The high acid content of a high acid product helps to
reduce bacteria growth in the product, thereby increasing the shelf
life of the product. The low acid content of a low acid product,
however, necessitates the use of more stringent packaging
techniques, and often requires refrigeration of the product at the
point of sale.
[0005] Several packaging techniques, including extended shelf life
(ESL) and aseptic packaging, have been developed to increase the
shelf life of low acid products. During ESL packaging, for example,
the packaging material is commonly sanitized and filled with a
product in a presterilized tunnel under "ultra-clean" conditions.
By using such ESL packaging techniques, the shelf life of an ESL
packaged product is commonly extended from about 10 to 15 days to
about 90 days. Aseptic packaging techniques, however, which require
that the packaging take place in a sterile environment, using
presterilized containers, etc., are capable of providing a packaged
product having an even longer shelf life of 150 days or more. In
fact, with aseptic packaging, the shelf life limitation is often
determined by the quality of the taste of the packaged product,
rather than by a limitation caused by bacterial growth.
[0006] For the aseptic packaging of food products, an aseptic
filler must, for example, use an FDA (Food and Drug Administration)
approved sterilant, meet FDA quality control standards, use a
sterile tunnel or clean room, and must aseptically treat all
packaging material. The food product must also be processed using
an "Ultra High Temperature" (UHT) pasteurization process to meet
FDA aseptic standards. The packaging material must remain in a
sterile environment during filling, closure, and sealing
operations.
[0007] Many attempts have been made, albeit unsuccessfully, to
aseptically fill containers, such as bottles or jars having small
openings, at a high output processing speed. In addition, previous
attempts for aseptically packaging a low acid product in plastic
bottles or jars (e.g., formed of polyethylene terepthalate (PET) or
high density polyethylene (HDPE)), at a high output processing
speed, have also failed. Furthermore, the prior art has not been
successful in providing a high output aseptic filler that complies
with the stringent United States FDA standards for labeling a
packaged product as "aseptic." In the following description of the
present invention, the term "aseptic" denotes the United States FDA
level of aseptic.
SUMMARY OF THE INVENTION
[0008] In order to overcome the above deficiencies, the present
invention provides a method and apparatus for providing aseptically
processed low acid products in a container having a small opening,
such as a glass or plastic bottle or jar, at a high output
processing speed.
[0009] Many features are incorporated into the aseptic processing
apparatus of the present invention in order to meet the various
United States FDA aseptic standards and the 3A Sanitary Standards
and Accepted Practices.
[0010] The aseptic processing apparatus of the present invention
uses filtered air to maintain a positive pressure within a filler
apparatus. The filler apparatus includes a sterile tunnel that is
pressurized to a level greater than atomospheric pressure using
filtered sterile air. The filler apparatus includes three
interfaces with the ambient environment, each of which eliminates
the possibility of external contamination. The first interface is
where containers first enter the sterile tunnel through a bottle
infeed and sterilization apparatus. In accordance with the present
invention, there is always an outflow of aseptic sterilant (e.g.,
hydrogen peroxide) enriched sterile air from the first interface to
prevent contaminants from entering the sterile tunnel. The second
interface with the sterile tunnel is the path where incoming lid
stock enters a lid sealing and heat sealing apparatus. To prevent
contamination, the lid stock passes through a hydrogen peroxide
bath that provides an aseptic barrier for any contaminants that
enter the sterile tunnel through the second interface. The third
interface with the sterile tunnel is at an exit opening of a
discharge apparatus where sealed containers leave the sterile
tunnel. Positive sterile air pressure within the sterile tunnel
ensures that sterile air is continuously flowing out of the exit
opening of the discharge apparatus, thereby preventing contaminants
from entering the sterile tunnel through this interface.
[0011] The aseptic processing apparatus includes a conveying
apparatus for transporting the containers through a plurality of
processing stations located within the sterile tunnel. The entire
conveying apparatus is enclosed within the sterile tunnel, and is
never is exposed to unsterile conditions.
[0012] The interior surface of a container such as a bottle or jar
is much more difficult to aseptically sterilize than the interior
surface of a cup. A cup generally has a large opening compared to
its height, whereas a bottle or jar generally has a small opening
compared to its height and its greatest width (e.g., the ratio of
the opening diameter to the height of the container is less than
1.0). A sterilant can be introduced, activated, and removed in a
cup much more rapidly than in a bottle or jar. The processing speed
when using a bottle or jar is limited, in part, by the time
required to aseptically sterilize the interior surface of the
bottle or jar. The aseptic processing apparatus of the present
invention overcomes the processing speed limitations associated
with the use of containers such as bottles or jars.
[0013] A high output processing speed is achieved in the present
invention by applying a hot atomized sterilant, such as a hydrogen
peroxide spray onto the interior surface of each container, and by
subsequently activating and removing the sterilant in a plurality
of drying stations using hot sterile air. For example hydrogen
peroxide breaks down into water and oxygen, and thus oxidizes and
kills bacteria within the container. To achieve aseptic
sterilization, a minimum container temperature is developed and
held for a predetermined period of time (e.g., 131.degree. F. for 5
seconds) after application of the sterilant. Hot sterile air is
delivered at a high volume and a relatively low temperature to dry
the container and to prevent the container (if formed of plastic)
from being heated to its softening temperature. After container
drying, the residual hydrogen peroxide in the container is below a
predetermined level (e.g., about 0.5 PPM (parts per million)).
[0014] The present invention generally provides a method for
aseptically bottling aseptically sterilized foodstuffs comprising
the steps of:
[0015] providing a plurality of bottles;
[0016] aseptically disinfecting the plurality of bottles;
[0017] aseptically filling the aseptically disinfected plurality of
bottles with the aseptically sterilized foodstuffs; and
[0018] filling the aseptically disinfected plurality of bottles at
a rate greater than 100 bottles per minute.
[0019] The present invention additionally provides a method for
aseptically bottling aseptically sterilized foodstuffs comprising
the steps of:
[0020] providing a plurality of bottles;
[0021] aseptically disinfecting the bottles at a rate greater than
100 bottles per minute; and
[0022] aseptically filling the bottles with aseptically sterilized
foodstuffs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The features of the present invention will best be
understood from a detailed description of the invention and a
preferred embodiment, thereof selected for the purposes of
illustration, and shown in the accompanying drawings in which:
[0024] FIG. 1 is a plan view of an aseptic processing apparatus in
accordance with a preferred embodiment of the present
invention;
[0025] FIG. 2 is a side view of the aseptic processing apparatus of
FIG. 1;
[0026] FIG. 3 is a partial cross-sectional side view of the aseptic
processing apparatus of FIG. 1;
[0027] FIG. 4 is a cross-sectional side view of a bottle infeed and
sterilization apparatus;
[0028] FIG. 5 illustrates a cross-sectional top view of the bottle
infeed and sterilization apparatus taken along line 5-5 of FIG.
4;
[0029] FIG. 6 is an interior sectional view of an interior wall
taken along line 6-6 of FIG. 4;
[0030] FIG. 7 is a cross-sectional view of the bottle infeed and
sterilization apparatus taken along line 7-7 of FIG. 4;
[0031] FIG. 8 is a perspective view of a conveying plate for use in
the aseptic processing apparatus of the present invention;
[0032] FIG. 9 is a perspective view of a partition in a sterile
tunnel;
[0033] FIG. 10 is a cross-sectional side view of an interior bottle
sterilization apparatus and the partition located between stations
8 and 9;
[0034] FIG. 11 is a cross-sectional side view of the partition
located between stations 22 and 23;
[0035] FIG. 12 is a cross-sectional side view of the partition
located between stations 35 and 36;
[0036] FIG. 13 is a cross-sectional side view of a lid
sterilization and heat sealing apparatus;
[0037] FIG. 14 is a side view of a lifting apparatus with a gripper
mechanism for lifting the bottles from the sterile tunnel;
[0038] FIG. 15 is a top view of the aseptic processing apparatus;
and
[0039] FIG. 16 is a side view of the aseptic processing apparatus
indicating the control and monitoring locations that are interfaced
with a control system.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Although certain preferred embodiments of the present
invention will be shown and described in detail, it should be
understood that various changes and modifications may be made
without departing from the scope of the appended claims. The scope
of the present invention will in no way be limited to the number of
constituting components, the materials thereof, the shapes thereof,
the relative arrangement thereof, etc., and are disclosed simply as
an example of the preferred embodiment. The features and advantages
of the present invention are illustrated in detail in the
accompanying drawings, wherein like reference numerals refer to
like elements throughout the drawings. Although the drawings are
intended to illustrate the present invention, the drawings are not
necessarily drawn to scale.
[0041] The present invention provides an aseptic processing
apparatus 10 that will meet the stringent FDA (Food and Drug
Administration) requirements and 3A Sanitary Standards and Accepted
Practices required to label a food product (foodstuffs) as
"aseptic". Hereafter, "aseptic" will refer to the FDA level of
aseptic. The present invention provides a method and apparatus for
producing at least about a 12 log reduction of Clostridium
botulinum in food products. In addition, the present invention
produces packaging material with at least about a 6 log reduction
of spores. Actual testing of the aseptic processing apparatus is
accomplished with spore test organisms. These test organisms are
selected on their resistance to the media selected used to achieve
sterility. For example, when steam is the media, the test organism
is Bacillus stearothermophilus. When hydrogen peroxide is the
media, then the test organism is Bacillus subtilis var.
globigii.
[0042] The present invention processes containers such as bottles
or jars that have a small opening compared to its height and its
greatest width (e.g., the ratio of the opening diameter to the
height of the container is less than 1.0). In the preferred
embodiment, a bottle 12 (see, e.g., FIG. 8) is illustrated as the
container. The container may alternately comprise a jar. The bottle
12 is preferably formed of a plastic such as polyethylene
terepthalate (PET) or high density polyethylene (HDPE), although
other materials such as glass may also be used. The present
invention uses an aseptic sterilant such as hydrogen peroxide
(H.sub.2O.sub.2) or oxonia to sterilize the bottles 12. In the
preferred embodiment of the present invention, hydrogen peroxide is
used as the sterilant. The present invention uses hydrogen peroxide
with a concentration of less than about 35% and ensures that the
bottles 12 have less than about 0.5 ppm of residual hydrogen
peroxide after each bottle 12 is sterilized.
[0043] FIGS. 1-3 illustrate several views of an aseptic processing
apparatus 10 in accordance with a preferred embodiment of the
present invention. As shown, the aseptic processing apparatus 10
includes a first bottle unscrambler 20, a second bottle unscramble
30, and a bottle lifter 40 for providing a supply of properly
oriented empty bottles. The empty bottles are delivered to a filler
apparatus 50 after passing through a bottle infeed and
sterilization apparatus 60 for aseptic sterilization. The filled
bottles are sealed at a first capping apparatus 400 or a second
capping apparatus 410. A control system 550 monitors and controls
the operation of the aseptic processing apparatus 10. The filled
and sealed bottles are packed and palletized using a first case
packing apparatus 480, a second case packing apparatus 490, a first
palletizer 500, and a second palletizer 510.
[0044] The bottles 12 arrive at a first bottle unscrambler 20 with
a random orientation, such that an opening 16 (see FIG. 8) of each
bottle 12 can be oriented in any direction. The first bottle
unscrambler 20 manipulates the bottles 12 until the opening 16 of
each bottle 12 is in a top vertical position. The bottles 12 leave
the first bottle unscrambler 20 in a series formation with the
opening 16 of each bottle 12 oriented vertically. The bottles 12
travel in single file in a first lane 18 to a first bottle lifter
40. The first bottle lifter 40 lifts and transports the bottles 12
to a bottle infeed and sterilization apparatus 60. A second bottle
unscrambler 30 may also used to provide a supply of vertically
oriented bottles 12. The bottles 12 output from the second bottle
unscrambler 30 travel in single file in a second lane 22 to a
second bottle lifter 42, which lifts and transports the bottles 12
to the bottle infeed and sterilization apparatus 60.
[0045] FIG. 3 illustrates the bottle infeed, sterilization, and
conveying apparatus 60 attached to the filler apparatus 50. FIG. 4
illustrates a cross-sectional side view of the bottle infeed,
sterilization, and conveying apparatus 60. FIG. 5 illustrates a
cross-sectional top view of the bottle infeed, sterilization, and
conveying apparatus 60 taken along line 5-5 of FIG. 4. The bottle
infeed and sterilization apparatus 60 preferably inputs six bottles
12 in a horizontal direction from the first lane 18 and six bottles
in a horizontal direction from the second lane 22 (FIG. 5). A gate
76 in the first lane 18 selectively groups six bottles 12 at a time
in first horizontal row 24. A gate 78 in the second lane 22
selectively groups six bottles 12 at a time in a second horizontal
row 28. An infeed apparatus 80 includes a pushing element 84 for
pushing the bottles 12 in the first horizontal row 24 into a first
vertical lane 26. A corresponding infeed apparatus 80 includes a
pushing element 86 for pushing the bottles 12 in the second
horizontal row 28 into a second vertical lane 32. The six bottles
12 in the first vertical lane 26 and the six bottles 12 in the
second vertical lane 32 are directed downward into the bottle
infeed and sterilization apparatus 60.
[0046] Referring to FIG. 4, as the bottles 12 move downward in the
first vertical lane 26 and the second vertical lane 32, a sterilant
14, such as heated hydrogen peroxide, oxonia, or other aseptic
sterilant, is applied to an outside surface 34 of each bottle 12 by
a sterilant application apparatus 36. The outside surface 34 of a
bottle 12 is illustrated in greater detail in FIG. 8. The bottles
12 may move downward in the first vertical lane 26 and the second
vertical lane 32 by the force of gravity. Alternatively, controlled
downward movement of the bottles 12 can be created by the use of a
conveying device such as a moving conveying chain. A plurality of
pins are attached to the conveying chain. Each bottle 12 rests on
one of the pins attached to the conveying chain. Therefore, the
motion of each bottle is controlled by the speed of the moving
conveying chain.
[0047] A sterilant such as hydrogen peroxide may be provided to the
sterilant application apparatus 36 in many ways. For example,
liquid hydrogen peroxide may be provided in a reservoir at a level
maintained by a pump and overflow pipe. A plurality of measuring
cups (e.g., approximately 0.5 ml each) connected by an air cylinder
are submerged into the reservoir and are lifted above the liquid
level. Thus, a measured volume of liquid hydrogen peroxide is
contained in each measuring cup.
[0048] Each measuring cup may include a conductivity probe that is
configured to send a signal to the control system 550 indicating
that the measuring cup is full. A tube (e.g., having a diameter of
about {fraction (1/16)}") is positioned in the center of the
measuring cup. A first end of the tube is positioned near the
bottom of the measuring cup. A second end of the tube is connected
to the sterilant application apparatus 36. The sterilant
application apparatus 36 includes a venturi and a heated double
tube heat exchanger. When the measuring cup is full, and a signal
is received from the control system 550, a valve is opened allowing
pressurized sterile air to enter the venturi. The pressurized air
flow causes a vacuum to be generated in second end of the tube
causing liquid hydrogen peroxide to be pulled out of the measuring
cup. The liquid hydrogen peroxide is sprayed into a sterile air
stream which atomizes the hydrogen peroxide into a spray. The
atomized hydrogen peroxide enters the double tube heat exchanger in
order to heat the atomized hydrogen peroxide to its vaporization
phase. The double tube heat exchanger is heated with steam and the
temperature is monitored and controlled by the control system 550.
In FIG. 4, the application of the sterilant 14 by the sterilant
application apparatus 36 is accomplished through the use of spray
nozzles 64 that produce a sterilant fog which is directed to the
outside surface 34 of each bottle 12.
[0049] Alternatively, a direct spray of heated hydrogen peroxide
may be continuously applied to the outside surface 34 of each
bottle 12. For producing the direct spray, a metering pump
regulates the amount of hydrogen peroxide, a flow meter
continuously measures and records the quantity of hydrogen peroxide
being dispensed, a spray nozzle produces a fine mist, and a heat
exchanger heats the hydrogen peroxide above the vaporization
point.
[0050] FIGS. 3 and 4 illustrate the sterilization chamber 38 for
activation and drying of bottles 12 which is included in the bottle
infeed, sterilization, and conveying apparatus 60. The
sterilization chamber 38 sterilizes the outside surface 34 of each
bottle 12. The sterilization chamber 38 encloses a conduit 39.
Sterile heated air, which is generated by a sterile air supply
system 146 (FIG. 3), enters the conduit 39 of the sterilization
chamber 38 through ports 64 and 68 located at the bottom of the
sterilization chamber 38. The sterile heated air also enters
through a bottom opening 62 of the bottle infeed and sterilization
apparatus 60. The sterile heated air travels up through the conduit
39 of the sterilization chamber 38, and exits the top of the
sterilization chamber 38 through an exhaust conduit 70. The sterile
heated air continuously flows in an upward direction through the
sterilization chamber 38, thus preventing any contaminants from
entering the bottle infeed and sterilization apparatus 60. To
create the sterile heated air, the air is first passed through a
filtering system (e.g., a group of double sterile air filters) to
sterilize the air. The air is then heated in a heating system
(e.g., an electric heater) to about 230.degree. F. The air
temperature is regulated by the control system 550. Other
techniques for providing the sterile heated air may also be used.
The control system 550 monitors the air pressure and flow rate of
the sterile heated air to ensure that an adequate flow of the hot
sterile air is maintained in the bottle sterilization chamber 38 of
the bottle infeed and sterilization apparatus 60.
[0051] As illustrated in FIGS. 4, 6, and 7, the sterilization
chamber 38 includes two opposing, interior, perforated walls 72A,
72B. The perforated walls 72A and 72B guide the bottles 12 downward
in the first vertical lane 26 and the second vertical lane 32,
respectively. The perforated walls 72A, 72B also allow the complete
circulation of hot sterile air around the outside surface 34 of
each bottle 12 in the sterilization chamber 38. The sterilization
chamber 38 supplies hot sterile air to the outside surface 34 of
each bottle 12 between the sterilant application apparatus 36 and
the bottom opening 62 of the bottle infeed and sterilization
apparatus 60. This sterilant may be hydrogen peroxide or oxonia
(hydrogen peroxide and peroxyacetic acid).
[0052] In accordance with the preferred embodiment of the present
invention, twelve drying positions are provided in the
sterilization chamber 38. Each bottle 12 is exposed to the hot
sterile air in the sterilization chamber 38 for about at least 24
seconds. This provides time sufficient time for the hydrogen
peroxide sterilant to break down into water and oxygen, to kill any
bacteria on the bottles 12, and to evaporate from the outside
surface 34 of the bottles 12.
[0053] An exhaust fan 73 is located at a top of the exhaust conduit
70 to provide an outlet from a sterile tunnel 90, and to control
the sterile air flow rate through the sterilization chamber 38. The
exhaust fan 73 is controlled by the control system 550. The control
system 550 controls the sterile air temperature preferably to about
230.degree. F., and controls the sterile air flow rate through the
sterilization chamber 38. The flow rate is preferably about 1800
scfm through the sterilization chamber 38. The bottles 12 leave the
sterilization chamber 38 with a hydrogen peroxide concentration of
less than 0.5 PPM.
[0054] As shown in FIGS. 3 and 4, a plurality of proximity sensors
71 located along the sides of the vertical lanes 26, 32 detect any
bottle 12 jams that occur within the sterilization chamber 38. The
proximity sensors 71 transmit an alarm signal to the control system
550. The bottles 12 leave the bottle infeed and sterilization
apparatus 60 through the bottom opening 62, and enter the sterile
tunnel 90 of the filler apparatus 50.
[0055] In the preferred embodiment of the present invention, the
filler apparatus 50 includes forty-one (41) index stations 92,
hereafter referred to as "stations." Various index stations 92 are
illustrated in FIGS. 3, 4, and 11-15. The conveying motion of the
bottles 12 to the various stations 92 through the filler apparatus
50 is based on an indexing motion. The filler apparatus 50 is
designed to convey the bottles 12 through the various operations of
the filler 50 in a two by six matrix. The twelve bottles 12 in the
two by six matrix are positioned in, and displaced by, a conveying
plate 94 as illustrated in FIG. 8. Therefore, twelve bottles 12 are
exposed to a particular station 92 at the same time. A conveying
apparatus 100 moves the set of twelve bottles 12 in each conveying
plate 94 sequentially through each station 92.
[0056] Referring to FIGS. 3 and 4, the bottles 12 are supplied from
an infeed chamber 102 to station 2 of the filler apparatus 50
through the bottom opening 62 of the bottle infeed and
sterilization apparatus 60. The infeed chamber 102 is enclosed to
direct heated hydrogen peroxide laden air completely around the
outer surface 34 of the bottles 12. A mechanical scissors mechanism
and a vacuum "pick and place" apparatus 104 position twelve bottles
12 at a time (in a two by six matrix, FIG. 8) into one of the
conveying plates 94.
[0057] A plurality of conveying plates 94 are attached to a main
conveyor 106. The main conveyor 106 forms a continuous element
around conveyor pulleys 108 and 110 as illustrated in FIG. 3. A
bottle support plate 107 supports a bottom 120 of each bottle 12 as
the bottles 12 are conveyed from station to station through the
filler apparatus 50. Each conveying plate 94 passes through
stations 1 through 41, around pulley 108, and returns around pulley
110 to repeat the process. The main conveyor 106, conveying plates
94, and pulleys 108 and 110 are enclosed in the sterile tunnel
90.
[0058] At station 4, the bottles 12 in the conveying plate 94 enter
a bottle detection apparatus 112. The bottle detection apparatus
112 determines whether all twelve bottles 12 are actually present
and correctly positioned in the conveying plate 94. Proximity
sensors 114 detect the presence and the alignment of each bottle
12. In the present invention, a bottle 12 with correct alignment is
in an upright position with the opening 16 of the bottle 12 located
in an upward position. Information regarding the location of any
misaligned or missing bottles 12 is relayed to the control system
550. The control system 550 uses this location information to
ensure that, at future stations 92, bottle filling or sealing will
not occur at the locations corresponding to the misaligned or
missing bottles 12.
[0059] At station 7, as illustrated in FIGS. 3 and 10, the bottles
12 in the conveying plate 94 enter an interior bottle sterilization
apparatus 116. A sterilant, such as hydrogen peroxide, oxonia, or
any other suitable aseptic sterilant is applied as a heated vapor
fog into the interior 118 of each bottle 12. Preferably, hydrogen
peroxide is used as the sterilant in the present invention. The
application of sterilant is accomplished with the use of a
plurality of sterilant measuring devices 120 and applicator spray
nozzles 122. A separate measuring device 120 and applicator spray
nozzle 122 are used for each of the twelve bottle 12 locations in
the conveying plate 94. Each bottle 12 is supplied with the same
measured quantity of sterilant, preferably in the form of a hot
vapor fog. The measured quantity of sterilant may be drawn from a
reservoir 124 of sterilant, heated, vaporized, etc., in a manner
similar to that described above with regard to the sterilant
application apparatus 36.
[0060] The control system 550 monitors and controls a spray
apparatus 126 that includes the applicator spray nozzles 122. Each
applicator spray nozzle 122 sprays the sterilant into the interior
118 of a corresponding bottle 12 as a hot vapor fog. The applicator
spray nozzles 122 are designed to extend through the bottle
openings 16. The applicator spray nozzles 122 descends into the
interior 118 and toward the bottom of the bottles 12. This ensures
the complete application of sterilant to the entire interior 118
and interior surface 119 of each bottle 12. Alternately, the
applicator spray nozzles 122 may be positioned immediately above
the bottle openings 16 prior to the application of sterilant.
[0061] FIG. 9 illustrates a perspective view of a partition 130
that provides control of sterile air flow within the sterile tunnel
90 of the filler apparatus 50. The partition 130 includes a top
baffle plate 132, a middle baffle plate 134, and a bottom baffle
plate 136. The top baffle plate 132 and the middle baffle plate 134
are provided with cut-outs 133 which correspond to the outer shape
of each bottle 12 and to the outer shape of the conveyor plate 94.
The cut-outs 133 allow each bottle 12 and each conveyor plate 94 to
pass through the partition 130. A space 138 between the middle
baffle plate 134 and the bottom baffle plate 136 allows each empty
conveyor plate 94 to pass through the partition 130 as it travels
on its return trip from the pulley 108 toward the pulley 110.
[0062] As illustrated in FIG. 3, partitions 130A, 130B, and 130C,
are located within the sterile tunnel 90. FIG. 10 illustrates a
cross-sectional view of partition 130A including baffle plates
132A, 134A, and 136A. The partition 130A is located between
stations 8 and 9. FIG. 11 illustrates a cross-sectional view of
partition 130B including baffle plates 132B, 134B, and 136B. The
partition 130B is located between stations 22 and 23. FIG. 12
illustrates a cross-sectional view of partition 130C including
baffles 132C, 134C, and 136C. The partition 130C is located between
stations 35 and 36. As illustrated in FIG. 3, sterile air is
introduced through sterile air conduits 140, 142, and 144 into the
sterile tunnel 90. The sterile air conduit 140 is located at
station 23 (FIG. 11), the sterile air conduit 142 is located at
station 27 (FIG. 3), and the sterile air conduit 144 is located at
station 35 (FIG. 12).
[0063] The partition 130A separates an activation and drying
apparatus 152 from the interior bottle sterilization apparatus 116.
The partition 130B separates the activation and drying apparatus
152 from a main product filler apparatus 160 and a lid
sterilization and heat sealing apparatus 162. Thus, a first
sterilization zone 164 is created that includes the activation and
drying apparatus 152. Partition 130C separates the main product
filler apparatus 160 and the lid sterilization and heat sealing
apparatus 162 from a bottle discharge apparatus 280. Thus,
partitions 130B and 130C create a second sterilization zone 166
that includes the main product filler apparatus 160 and the lid
sterilization and heat sealing apparatus 162. A third sterilization
zone 172 includes the bottle discharge apparatus 280. A fourth
sterilization zone 165 includes the interior bottle sterilization
apparatus 116. The second sterilization zone 166 provides a highly
sterile area where the bottles 12 are filled with a product and
sealed. The second sterilization zone 166 is at a higher pressure
than the first sterilization zone 164 and the third sterilization
zone 172. Therefore, any gas flow leakage is in the direction from
the second sterilization zone 166 out to the first sterilization
zone 164 and the third sterilization zone 172. The first
sterilization zone 164 is at a higher pressure than the fourth
sterilization zone 165. Therefore, gas flow is in the direction
from the first sterilization zone 164 to the fourth sterilization
zone 165.
[0064] The partitions 130A, 130B, and 130C create sterilization
zones 164, 165, 166, and 172 with different concentration levels of
gas laden sterilant (e.g., hydrogen peroxide in air). The highest
concentration level of sterilant is in the fourth sterilization
zone 165. An intermediate concentration level of sterilant is in
the first sterilization zone 164. The lowest concentration level of
sterilant is in the second sterilization zone 166. Advantageously,
this helps to maintain the main product filler apparatus 160 and
the lid sterilization and heat sealing apparatus 162 at a low
sterilant concentration level. This prevents unwanted high levels
of sterilant to enter the food product during the filling and
lidding process.
[0065] Stations 10 through 21 include twelve stations for directing
hot sterile air into each bottle 12 for the activation and removal
of the sterilant from the interior of the bottle 12. The sterile
air supply system 146 supplies hot sterile air to a plurality of
nozzles 150 in the activation and drying apparatus 152. Hot sterile
air is supplied to the sterile air supply system 146 through
conduit 148. The air is first passed through a filtration system to
sterilize the air. The air is then heated in a heating system to
about 230.degree. F. The air temperature is regulated by the
control system 550. Also, the control system 550 monitors the air
pressure and flow rate to ensure that an adequate flow of hot
sterile air is maintained in the sterile tunnel 90 of the
application and drying apparatus 152.
[0066] As shown in FIG. 8, each bottle 12 generally has a small
opening 16 compared to its height "H." A ratio of a diameter "D" of
the bottle 12 to the height "H" of the bottle 12 is generally less
than 1.0. The small bottle opening 16 combined with a larger height
"H" restricts the flow of hot gas into the interior 118 of the
bottle 12. Also, PET and HDPE bottle materials have low heat
resistance temperatures. These temperatures commonly are about
55.degree. C. for PET and about 121.degree. C. for HDPE. Typically,
in the aseptic packaging industry, a low volume of air at a high
temperature is applied to the packaging materials. This often
results in deformation and softening of packaging materials formed
of PET and HDPE. In order to prevent softening and deformation of
the bottles 12, when formed from these types of materials, the
present invention applies high volumes of air at relatively low
temperatures over an extended period of time in the activation and
drying apparatus 152. The plurality of nozzles 150 of the
activation and drying apparatus 152 direct hot sterile air into the
interior 118 of each bottle 12 (FIG. 11). A long exposure time is
predicated by the geometry of the bottle 12 and the softening
temperature of the material used to form the bottle 12. In the
present invention, about 24 seconds are allowed for directing hot
sterile air from the plurality of nozzles 150 into each bottle for
the activation and removal of sterilant from the interior surface
119 of the bottle 12. To achieve aseptic sterilization, a minimum
bottle temperature of about 131.degree. F. should be held for at
least 5 seconds. To achieve this bottle temperature and time
requirements, including the time required to heat the bottle, the
sterilant is applied for about 1 second and the hot sterile air is
introduced for about 24 seconds. The hot sterile air leaves the
nozzles 150 at about 230.degree. F. and cools to about 131.degree.
F. when it enters the bottle 12. The hot sterile air is delivered
at a high volume so that the bottle 12 is maintained at about
131.degree. F. for at least 5 seconds. The about 24 seconds
provides adequate time for the bottle 12 to heat up to about
131.degree. F. and to maintain this temperature for at least 5
seconds. After bottle 12 has dried, the residual hydrogen peroxide
remaining on the bottle 12 surface is less than 0.5 PPM.
[0067] A foodstuff product is first sterilized to eliminate
bacteria in the product. An "Ultra High Temperature" (UHT)
pasteurization process is required to meet the aseptic FDA
standard. The time and temperature required to meet the aseptic FDA
standard depends on the type of foodstuff. For example, milk must
be heated to 282.degree. F. for not less than 2 seconds in order to
meet the aseptic standards.
[0068] After UHT pasteurization, the product is delivered to a main
product filler apparatus 160. The main product filler apparatus is
illustrated in FIGS. 3 and 13. The main product filler 160 can be
sterilized and cleaned in place to maintain aseptic FDA and 3A
standards. A pressurized reservoir apparatus 180 that can be steam
sterilized is included in the main product filler apparatus 160. As
illustrated in FIG. 13, the pressurized reservoir apparatus 180
includes an enclosed product tank 182 with a large capacity (e.g.,
15 gallons). The product tank 182 is able to withstand elevated
pressures of about 60 psig or more. The pressurized reservoir
apparatus 180 also includes a level sensor 184, a pressure sensor
186, a volumetric measuring device 188, and a filling nozzle 190.
The product tank 182 includes a single inlet with a valve cluster
including a sterile barrier to separate the product process system
from aseptic surge tanks and the main product filler apparatus 160.
The product tank 182 has an outlet with twelve connections. At each
connections is a volumetric measuring device 188 such as a mass or
volumetric flow meter. A plurality of filling nozzles 190A, 190B
are provided at stations 23, 25, respectively. In addition, there
are a plurality of volumetric measuring devices 188A and 188B to
measure the volume of product entering each bottle 12 at stations
23 and 25, respectively. The control system 550 calculates the
desired volume of product to be inserted into each bottle 12, and
controls the product volume by opening or closing a plurality of
valves 194A and 194B. The activation mechanisms for valves 194A and
194B have a sterile barrier to prevent contamination of the
product. The plurality of valves 194A control the volume of product
flowing through a corresponding plurality of nozzles 196A into the
bottles 12 at station 23. The plurality of valves 194B control the
volume of product flowing through a corresponding plurality of
nozzles 196B into the bottles 12 at station 25. The control system
550 uses the previously stored information provided by the bottle
detection apparatus 112 to only allow filling to occur at the
locations where bottles 12 are actually present and correctly
aligned.
[0069] The initial sterilization process for the pressurized
reservoir apparatus 180 includes the step of exposing all of the
surfaces of the pressurized reservoir apparatus 180 that come in
contact with the product to steam at temperatures above about
250.degree. F. for a minimum of about 30 minutes. Elements such as
cups 198A and 198B are used to block off nozzle outlets 196A and
196B respectively, to allow a build-up of steam pressure to about
50 psig inside the pressurized reservoir apparatus 180. Condensate
generated as the steam heats the interior surfaces of the
pressurized reservoir apparatus 180 is collected and released from
the nozzles 198A and 198B. This condensate is released when the
cups 198A and 198B are removed from the nozzle outlets 196A and
196B. Once the interior surfaces of the pressurized reservoir
apparatus 180 are sterilized, the steam is shut off, and sterile
air is used to replace the steam. The sterile air reduces the
interior temperature of the pressurized reservoir apparatus 180 to
the temperature of the product before the product is allowed to
enter the enclosed product tank 182. Sterile air is directed
through sterile air conduits 142 and 144 into the second
sterilization zone 166 at a volume rate of about 800 scfm (FIG.
13). The sterile air flow entering the second sterilization zone
166 provides sterile air to the main product filler apparatus 160
and to the lid sterilization and heat sealing apparatus 162.
[0070] The main product filler apparatus 160 includes a separate
filling position for each bottle. The bottle 12 filling operation
is completed for six bottles at station 23 and for six bottles at
station 25.
[0071] FIGS. 3 and 13 illustrate the lid sterilization and heat
sealing apparatus 162. A lid 200 is applied to each of the twelve
bottles 12 at station 31. For a fully aseptic bottle filler,
complete lid 200 sterilization is necessary, and therefore a
sterilant such as hydrogen peroxide is typically used. In the
present invention, the lids are formed of a material such as foil
or plastic. The lids 200 are joined together by a small
interconnecting band that holds them together to form a long
connected chain of lids 200, hereinafter referred to as a "daisy
chain" 202. A daisy chain 202 of lids 200 is placed on each of a
plurality of reels 210. For the twelve bottle configuration of the
present invention, six of the reels 210, each holding a daisy chain
202 of lids 200, are located on each side of a heat sealing
apparatus 214. Each daisy chain 202 of lids 200 winds off of a
corresponding reel 210 and is sterilized, preferably using a
hydrogen peroxide bath 204. A plurality of hot sterile air knives
208, which are formed by jets of hot sterile air, activate the
hydrogen peroxide to sterilize the lids 200 on the daisy chain 202.
The hot sterile air knives 208 also remove the hydrogen peroxide
from the lids 200 so that the residual concentration of hydrogen
peroxide is less than 0.5 PPM. The hydrogen peroxide bath 204
prevents any contaminants from entering the sterile tunnel 90 via
the lidding operation. Once sterilized, the lids 200 enter the
sterile tunnel 90 where they are separated from the daisy chain 202
and placed on a bottle 12. Each lid is slightly larger in diameter
then that of the opening 16 of a bottle 12. During the placement of
the lid 200 on the bottle 12, a slight mechanical crimp of the lid
200 is formed to locate and hold the lid 200 on the bottle 12. The
crimp holds the lid 200 in place on the bottle 12 until the bottle
12 reaches a station 33 for sealing.
[0072] At station 33, the lids 200 are applied to the bottles 12.
The heat sealing apparatus 214 includes a heated platen 216 that
applies heat and pressure against each lid 200 for a predetermined
length of time, to form a seal between the lid 200 and the bottle
12. The heated platen 216 is in a two by six configuration to seal
twelve of the bottles 12 at a time.
[0073] At station 37, the lid 200 seal and bottle 12 integrity are
checked in a known manner by a seal integrity apparatus (not shown)
comprising, for example, a bottle squeezing mechanism and a
proximity sensor. Each bottle 12 is squeezed by the bottle
squeezing mechanism which causes the lid 200 on the bottle 12 to
extend upward. The proximity sensor detects if the lid 200 has
extended upward, which indicates an acceptable seal, or whether the
seal remains flat, which indicates a leaking seal or bottle 12. The
location of the defective bottles 12 are recorded by the control
system 550 so that the defective bottles will not be packed.
[0074] Bottle discharge from the sterile tunnel 90 of the filler
apparatus 50 occurs at stations 38 and 40 as illustrated in FIGS.
3, 13 and 14. A bottle discharge apparatus 280 is located at
stations 38 and 40. At this point in the filler apparatus 50, the
filled and sealed bottles 12 are forced in an upward direction such
that a top portion 284 of each bottle 12 protrudes through an
opening 282 in the sterile tunnel 90 (FIG. 14). A rotating cam 290
or other suitable means (e.g., an inflatable diaphragm, etc.) may
be used to apply a force against the bottom 120 of each bottle 12
to force the bottle 12 in an upward direction.
[0075] As illustrated in FIG. 14, the bottle discharge apparatus
280 comprises a lifting apparatus 286 that includes a gripper 288
that grasps the top portion 284 of each bottle 12 and lifts the
bottle 12 out through the opening 282 in the sterile tunnel 90. In
order to ensure that contaminated air cannot enter the sterile
tunnel 90, the sterile air in the sterile tunnel 90 is maintained
at a higher pressure than the air outside the sterile tunnel 90.
Thus, sterile air is always flowing out of the sterile tunnel 90
through the opening 282. In addition, the gripper 288 never enters
the sterile tunnel 90, because the top portion 284 of the bottle 12
is first lifted out of the sterile tunnel 90 by the action of the
rotating cam 290 before being grabbed by the gripper 288.
[0076] FIG. 15 illustrates a top view of the filler apparatus 50
including the bottle infeed and sterilization apparatus 60, the
interior bottle sterilization apparatus 116, and the activation and
drying apparatus 152. FIG. 15 additionally illustrates the main
filler apparatus 160, the lid sterilization and heat sealing
apparatus 162, and the bottle discharge apparatus 280.
[0077] Referring again to FIGS. 1 and 14, the lifting apparatus 286
lifts the bottles 12 at station 38 and places the bottles 12 in a
first lane 292 that transports the bottles 12 to a first capping
apparatus 410. In addition, the lifting apparatus 286 lifts the
bottles 12 at station 40 and places the bottles 12 in a second lane
294 that transports the bottles 12 to a second capping apparatus
400.
[0078] The first capping apparatus 410 secures a cap (not shown) on
the top of each bottle 12 in the first lane 292. The second capping
apparatus 400 secures a cap on the top of each bottle 12 in the
second lane 294. The caps are secured to the bottles 12 in a manner
known in the art. It should be noted that the capping process may
be performed outside of the sterile tunnel 90 because each of the
bottles 12 have previously been sealed within the sterile tunnel 90
by the lid sterilization and heat sealing apparatus 162 using a
sterile lid 200.
[0079] After capping, the bottles 12 are transported via the first
and second lanes 292, 294 to labelers 460 and 470. The first
labeling apparatus 470 applies a label to each bottle 12 in the
first lane 292. The second labeling apparatus 460 applies a label
to each bottle 12 in the second lane 294.
[0080] From the first labeling apparatus 470, the bottles 12 are
transported along a first set of multiple lanes (e.g., 4) to a
first case packing apparatus 490. From the second labeling
apparatus 460, the bottles 12 are transported along a second set of
multiple lanes to a second case packing apparatus 480. Each case
packing apparatus 480, 490 gathers and packs a plurality of the
bottles 12 (e.g., twelve) in each case in a suitable (e.g., three
by four) matrix.
[0081] A first conveyor 296 transports the cases output by the
first case packer 490 to a first palletizer 510. A second conveyor
298 transports the cases output by the second case packer 480 to a
second palletizer 500. A vehicle, such as a fork lift truck, then
transports the pallets loaded with the cases of bottles 12 to a
storage warehouse.
[0082] Referring again to FIG. 3, the main conveyor 106 and each
conveying plate 94 are cleaned and sanitized once during each
revolution of the main conveyor 106. Specifically, after each empty
conveying plate 94 passes around the pulley 108, the conveying
plate 94 is passed through a liquid sanitizing apparatus 300 and a
drying apparatus 302. The liquid sanitizing apparatus 300 sprays a
mixture of a sterilizing agent (e.g., oxonia, (hydrogen peroxide
and peroxyacetic acid)) over the entire surface of each conveying
plate 94 and associated components of the main conveyor 106. In the
drying apparatus 302, heated air is used to dry the main conveyor
106 and conveying plates 94.
[0083] Stations 1 through 40 are enclosed in the sterile tunnel 90.
The sterile tunnel 90 is supplied with air that is pressurized and
sterilized. The interior of the sterile tunnel 90 is maintained at
a pressure higher than the outside environment in order to
eliminate contamination during the bottle processing. In addition,
to further ensure a sterile environment within the sterile tunnel
90, the sterile air supply provides a predetermined number of air
changes (e.g., 2.5 changes of air per minute) in the sterile tunnel
90.
[0084] The bottle infeed and sterilization apparatus 60 and the
filler apparatus 50 meet the 3A Sanitary Standards of the Sanitary
Standards Symbol Administrative Council. The 3A Sanitary Standards
ensure that all product contact surfaces can be cleaned and
sterilized on a regular basis such as daily. The present invention
allows the product contact surfaces to be cleaned-in-place without
dismantling the bottle infeed and sterilization apparatus 60 or the
filler apparatus 50. The 3A Sanitary Standards includes
requirements such as the material type, the material surface
finish, the elastomer selection, the radius of machined parts and
the ability of all surfaces to be free draining. For example, the
material type is selected from the 300 series of stainless steel
and all product contact surfaces have a finish at least as smooth
as No. 4 ground finish on stainless steel sheets.
[0085] Before bottle production is initiated, the bottle infeed and
sterilization apparatus 60 and the filler apparatus 50 are
preferably sterilized with an aseptic sterilant. For example, a
sterilant such as a hot hydrogen peroxide mist may be applied to
all interior surfaces of the bottle infeed and sterilization
apparatus 60 and the filler apparatus 50. Then, hot sterile air is
supplied to activate and remove the hydrogen peroxide, and to dry
the interior surfaces of the bottle infeed and sterilization
apparatus 60 and the filler apparatus 50.
[0086] FIG. 16 is a side view of the aseptic processing apparatus
10 of the present invention indicating the location of the control
and monitoring devices that are interfaced with the control system
550. The control system 550 gathers information and controls
process functions in the aseptic processing apparatus 10. A
preferred arrangement of the control and monitoring devices are
indicated by encircled letters in FIG. 16. A functional description
of each of the control and monitoring devices is listed below. It
should be noted that these control and monitoring devices are only
representative of the types of devices that may be used in the
aseptic processing apparatus 10 of the present invention. Other
types and combinations of control and monitoring devices may be
used without departing from the intended scope of the present
invention. Further, control system 550 may respond in different
ways to the outputs of the control and monitoring devices. For
example, the control system 550 may automatically adjust the
operational parameters of the various components of the aseptic
processing apparatus 10, may generate and/or log error messages, or
may even shut down the entire aseptic processing apparatus 10. In
the preferred embodiment of the present invention, the control and
monitoring devices include:
[0087] A. A bottle counter to ensure that a predetermined number of
the bottles 12 (e.g., six bottles) on each upper horizontal row 24,
28 enter the loading area of the bottle infeed and sterilization
apparatus 60.
[0088] B. A proximity sensor to ensure that the first group of
bottles 12 has dropped into the first bottle position in the bottle
infeed and sterilization apparatus 60.
[0089] C1. A conductivity sensor to ensure that the measuring cup
used by the sterilant application apparatus 36 is full.
[0090] C2. A conductivity sensor to ensure that the measuring cup
used by the sterilant application apparatus 36 is emptied in a
predetermined time.
[0091] C3. A pressure sensor to ensure that the pressure of the air
used by the sterilant application apparatus 36 is within
predetermined atomization requirements.
[0092] C4. A temperature sensor to ensure that each heat heating
element used by the sterilant application apparatus 36 is heated to
the correct temperature.
[0093] D. A proximity sensor (e.g., proximity sensor 71, FIG. 3) to
ensure that a bottle jam has not occurred within the bottle infeed
and sterilization apparatus 60.
[0094] E. A temperature sensor to ensure that the temperature of
the heated sterile air entering the bottle infeed and sterilization
apparatus 60 is correct.
[0095] F. A proximity sensor that to ensure that each conveying
plate 94 is fully loaded with bottles 12.
[0096] G1. A conductivity sensor to ensure that the measuring cup
used by the interior bottle sterilization apparatus 116 is
full.
[0097] G2. A conductivity sensor to ensure that the measuring cup
used by the interior bottle sterilization apparatus 116 is emptied
in a predetermined time.
[0098] G3. A pressure sensor to ensure that the pressure of the air
used by the interior bottle sterilization apparatus 116 is within
predetermined atomization requirements.
[0099] G4. A temperature sensor to ensure that each heat heating
element used by the interior bottle sterilization apparatus 116 is
heated to the correct temperature.
[0100] H. A temperature sensor to ensure that the air drying
temperature within the activation and drying apparatus 152 is
correct.
[0101] I. A plurality of flow sensors to ensure that the airflow
rate of the sterile air entering the sterile tunnel 90 is
correct.
[0102] J. A pressure sensor to ensure that the pressure of the
sterile air entering the activation and drying apparatus 152 is
correct.
[0103] K. A measuring device (e.g., volumetric measuring device
188, FIG. 3) to ensure that each bottle 12 is filled to a
predetermined level.
[0104] L. A pressure sensor to ensure that the pressure in the
product tank 182 is above a predetermined level.
[0105] M. A level sensor to ensure that the level of product in the
product tank 182 is maintained at a predetermined level.
[0106] N. Proximity sensors to ensure that the daisy chains 202 of
lids 200 are present in the lid sterilization and heat sealing
apparatus 162
[0107] O. A level sensor to ensure that the hydrogen peroxide level
in the hydrogen peroxide bath 204 in the lid sterilization and heat
sealing apparatus 162 is above a predetermined level.
[0108] P. A temperature sensor to ensure that the temperature of
the hot sterile air knives 208 of the lid sterilization and heat
sealing apparatus 162 is correct.
[0109] Q. A temperature sensor to ensure that the heat sealing
apparatus 214 is operating at the correct temperature.
[0110] R. Proximity sensors to ensure that the bottles 12 are
discharged from the filler.
[0111] S. A speed sensor to measure the speed of the conveying
apparatus 100.
[0112] T. A concentration sensor to ensure that the concentration
of oxonia is maintained at a predetermined level in the sanitizing
apparatus 300.
[0113] U. A pressure sensor to ensure that the pressure of the
oxonia is maintained above a predetermined level in the sanitizing
apparatus 300.
[0114] V. A temperature sensor to ensure that the drying
temperature of the drying apparatus 302 is correct.
[0115] The foregoing description of the present invention has been
presented for purposes of illustration and description. It is not
intended to be exhaustive or to limit the invention to the precise
form disclosed, and many modifications and variations are possible
in light of the above teaching. Such modifications and variations
that may be apparent to a person skilled in the art are intended to
be included within the scope of this invention defined by the
accompanying claims.
* * * * *