U.S. patent application number 13/049548 was filed with the patent office on 2011-09-22 for apparatus and method for the hot filling of beverages.
Invention is credited to Jochen Hirdina.
Application Number | 20110225932 13/049548 |
Document ID | / |
Family ID | 44140701 |
Filed Date | 2011-09-22 |
United States Patent
Application |
20110225932 |
Kind Code |
A1 |
Hirdina; Jochen |
September 22, 2011 |
APPARATUS AND METHOD FOR THE HOT FILLING OF BEVERAGES
Abstract
The invention relates to a method of producing beverage
containers (10) with the steps: producing a plastics material
container (10), wherein the plastics material container (10) is
produced from a plastics material pre-form by means of a shaping
device (2); conveying the container (10) to a filling device (4)
filling the container (10) with a liquid and, in particular with a
beverage, wherein the liquid is filled into the container (10) at a
temperature which is above 50.degree. C., wherein the container
(10) is sterilized between a separating device arranged upstream of
a pre-form inlet of the shaping device (2) and the filling device
(4).
Inventors: |
Hirdina; Jochen;
(Regensburg, DE) |
Family ID: |
44140701 |
Appl. No.: |
13/049548 |
Filed: |
March 16, 2011 |
Current U.S.
Class: |
53/426 ; 53/127;
53/167; 53/440; 53/456; 53/467; 53/563 |
Current CPC
Class: |
B29C 49/4268 20130101;
B67C 2003/227 20130101; B65B 55/10 20130101; B29C 49/4252 20130101;
B67C 3/045 20130101 |
Class at
Publication: |
53/426 ; 53/440;
53/456; 53/467; 53/563; 53/127; 53/167 |
International
Class: |
B65B 55/04 20060101
B65B055/04; B65B 63/08 20060101 B65B063/08; B65B 43/08 20060101
B65B043/08; B65B 7/00 20060101 B65B007/00; B65B 3/02 20060101
B65B003/02 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 19, 2010 |
DE |
10 2010 012 211.4 |
Claims
1. A method of producing beverage containers with the steps:
producing a plastics material container, wherein the plastics
material container is produced from a plastics material pre-form
using a shaping device; conveying the container to a filling
device; filling the container with a liquid and, in particular with
a beverage, wherein the liquid is filled into the container at a
temperature which is above 50.degree. C., wherein the container is
sterilized between a separating device for the plastics material
pre-forms arranged upstream of a pre-form inlet of the shaping
device and the filling device.
2. A method according to claim 1, wherein the container is
sterilized in the shaping device.
3. A method according to claim 1, wherein the container is cooled
after the filling.
4. A method according to claim 3, wherein the container is cooled
by being acted upon with a flowable medium.
5. A method according to claim 1, wherein the container is closed
immediately after the filling.
6. A method according to claim 1, wherein a closure of the
container is likewise sterilized.
7. A method according to claim 1, wherein the container is conveyed
through a sterile environment between the shaping device and the
filling device.
8. An apparatus for producing filled containers, with a shaping
device which shapes plastics material pre-forms to form plastics
material containers, with a conveying device which conveys the
plastics material containers away from the shaping device, and with
a filling device which is arranged downstream with respect to the
shaping device along a conveying path of the plastics material
containers and which fills the containers with a liquid, wherein
the filling device is designed in such a way that it fills the
liquid at a temperature of more than 50.degree. C. into the
containers, wherein the apparatus has a sterilization device which
is arranged between a separating device arranged upstream of a
pre-form inlet of the shaping device and the filling device and
which sterilizes the containers.
9. An apparatus according to claim 8, wherein the apparatus has a
application device which is arranged downstream of the filling
device along the conveying path of the containers and which acts
upon the filled containers with a flowable medium.
10. An apparatus according to claim 8, wherein the apparatus has a
cooling device arranged downstream of the filling device for
cooling the filled containers.
11. An apparatus according to claim 8, wherein a sterile room,
through which the container is conveyed, is arranged between the
shaping device and the filling device.
Description
[0001] The present invention relates to a method and an apparatus
for producing filled beverage containers and, in particular to a
method and an apparatus in which beverages are filled hot. It is
known from the prior art that various beverages such as for example
iced tea are filled hot. This hot filling poses problems, in
particular in the case of plastics material containers or PET
containers. In the hot filling of PET containers in fact the
thermal stability of the material and the vacuum stability of the
container represent a major challenge. The material of PET has a
relatively low glass transition temperature of approximately
75.degree. C. This is not sufficient for the filling temperature of
sensitive products which as a rule is between 85.degree. C. and
92.degree. C. For this reason the material is thermally
crystallized during the treatment in the stretching blow moulding
machine. This is carried out by way of a high pre-form temperature
and by way of heated blow moulds (temperatures of between
120.degree. C. and 160.degree. C.). On the other hand, however,
this leads to a significantly higher energy consumption since
cooling of the container is additionally required by way of
compressed air before deformation occurs. A further drawback is the
limited output performance on account of the necessary
crystallization period in the blow mould.
[0002] The higher the filling temperature, the more problematic the
thermal stability becomes, and the output performance has to be
drastically reduced in part. In addition, this procedure results in
a relatively high weight of the containers.
[0003] DE 36 50 667 T2 describes a method of producing a
deformation-resistant polyester container which is capable of being
hot filled. In this case a plastics material pre-form is produced,
and it is heated and placed in a blow mould cavity. Furthermore, it
is necessary to observe specific drawing ratios of the wall of the
pre-form which are between 8:1 and 12:1. In addition, the
temperature of the re-heated pre-form is maintained between
82.degree. C. and 121.degree. C.
[0004] DE 698 02 357 T2 describes an apparatus for the sterile
filling and packing of foods. This apparatus has a sterilization
portion for sterilizing packing containers filled with solid or
liquid foods as well as a packing portion for hermetically sealing
the packing containers.
[0005] A filling machine with liquid circulation is known from EP 1
559 674 B1. In this case a charge is also filled hot into bottles
and, in order to prevent the charge from cooling in the filling
elements, the charge is conveyed in the hot state in at least one
flow path including the filling elements whilst interrupting the
filling process.
[0006] A further method of hot filling beverages is known from U.S.
Pat. No. 5,251,424. In this case too a plastics material container
is made available and after that the hot beverage is filled into
it. After that the container is closed and the contents of the
container are held under pressure
[0007] A method of low-germ filling of plastics bottles is known
from DE 195 20 925 A1. In this case after the filling and closure
each container is subjected to a thermal after-treatment in which
the charge is held in the interior of the respective container at a
temperature of at least 60.degree. C.
[0008] The object of the present invention is to treat the
respective plastics material containers as gently as possible even
in the case of beverages which are to be filled hot. This is
attained according to the invention by a method and an apparatus in
accordance with the independent claims. Advantageous embodiments
and further developments form the subject matter of the
sub-claims.
[0009] In the case of a method according to the invention for
producing filled beverage containers a plastics material container
is first produced, the plastics material container being produced
from a plastics material pre-form by means of a shaping device.
After that, the container is conveyed to a filling device and is
filled with a liquid and, in particular with a beverage, in which
case the liquid is filled into the container at a temperature which
is above 50.degree. C.
[0010] According to the invention the container is sterilized at
least in part between the shaping device and the filling device, or
expressed in more precise terms, between a separating device for
separating the plastics material pre-forms arranged upstream of a
pre-form inlet of the blow moulding machine and the filling device.
It is preferable for an inner wall of the container to be
sterilized at least in part and is preferably sterilized
completely. In addition, however, it is also possible for
sterilization of an outer surface of the container to be carried
out at least in part. In this way, it is preferable for this
separating device for separating the plastics material pre-forms
also to be regarded as being a component part of the shaping device
within the context of this description. It is preferable for the
separating device to be arranged between the inlet of the shaping
device and the filling device.
[0011] The term "blow moulding machine" refers in the following not
only to the actual blow moulding module which shapes the plastics
material pre-forms into plastics material containers, but also to
apparatus arranged upstream of this blow moulding module, such as
in particular but not exclusively a heating device or a furnace,
which heats the plastics material pre-forms. In this case the
pre-form inlet can be in particular that area at which the
pre-forms arrive in the aforesaid heating device. In particular,
sterilization in an area of the heating device would thus also be
possible. It would also be possible, however, for the pre-forms
heated in the heating device to be sterilized before, during or
after their entry into the blow moulding module.
[0012] The shaping device is in particular a blow moulding machine
and, in a particularly preferred manner, a stretching blow moulding
machine. The high filling temperature is necessary in particular on
microbiological grounds. In this case the charge has to be heated
to a temperature dependent upon the product in order to achieve an
adequate sterilization effect against the germ spores etc. which
exist. As a result of this destruction of pathogens a longer
storage life of the charge is achieved. It is preferable for the
charge to be filled at a temperature which is above 60.degree. C.,
preferably above 70.degree. C. and in a particularly preferred
manner above 75.degree. C. In order to ensure that all pathogens
are destroyed even on the path of the product into the container
and in the container, the product has to be filled hot and not only
sterilized in the course of a heating of short duration. In this
case the prior art provides for a certain standing time of the hot
liquid in the bottle, which as a rule lasts between one and five
minutes for this microbiological safeguard. On the other hand, this
very standing time has the effect that the PET container is
difficult to keep dimensionally stable since the strength of the
material is sharply reduced.
[0013] With the method proposed according to the invention it is
therefore made possible for a product to be filled in a
microbiologically safe manner without the complication of an
aseptic procedure being required. On account of the heavy weight of
the bottles, the hot filling already described in the prior art is
economic to only a limited degree and is improved by way of the
present invention in such a way as to result in an economic filling
method. It is advantageous for the sterilization of the container
to be carried out by acting upon it with a sterilizing agent and,
in particular, with hydrogen peroxide gas.
[0014] It is advantageous for the container to be sterilized in the
shaping device. In this case it is possible for the containers to
be sterilized in the shaping device for example of the blow
moulding machine. This sterilization of the container produced is
now combined with the hot filling in order to avoid in this way the
necessary standing time of the container at a hot temperature.
[0015] In the case of a further advantageous method the container
is cooled after the filling (in particular immediately afterwards).
In this way an additional protection of the containers is possible.
It is thus possible for the containers to be conveyed directly into
a heat exchanger downstream of the filling device. In this case, as
compared with the prior art, the conveying path is dispensed with
which is otherwise present between the filling device and this heat
exchanger.
[0016] In the case of a further advantageous method the cooling of
the filled containers is carried out without further head space
sterilization of the filled containers. It is preferable for the
cooling to be carried out at a temperature of below 50.degree. C.
If products, the temperature of which is above 85.degree. C., are
filled, sterilization of the filling device itself is also effected
by the product.
[0017] In addition, it is possible to dispense with neck
sterilizers. In this way, the container is cooled down from the
critical temperature range of over 80.degree. C., in particular
after the filling, so that the PET does not pass into a weakened
state in which it could become dimensionally unstable. It is
preferable for the shaping unit and the filling device to be
operated in a block arrangement or in synchronism, and it is
particularly preferred for these blocks to be complemented by a
heat exchanger.
[0018] It is advantageous for the container to be cooled by being
acted upon with a flowable medium. It thus can be sprayed with
water for example in order to be cooled in this way. Cooling with
air, however, would also be possible.
[0019] In the case of a further advantageous method the container
is closed immediately after the filling. It is advantageous for the
disinfection or the sterilization of the individual closures to be
carried out during this. In this case too this sterilization can be
carried out with a gaseous medium, such as in particular but not
exclusively hydrogen peroxide (H.sub.2O.sub.2).
[0020] In the case of a further advantageous method the closure of
the container is likewise sterilized. It is advantageous for the
closure to be sterilized before the closing procedure. In this
case, in particular, sterilization of the interior of the closure
takes place, i.e. of that region which bounds the interior of the
closed container.
[0021] It is advantageous for the container to be conveyed through
a sterile environment between the shaping device and the filling
device. In this way it is possible for the container no longer to
be contaminated after the shaping procedure. This can be for
example a sterile room which extends from the shaping device to the
filling device. It is thus advantageous for the filling device also
to adjoin the shaping device at a relatively short distance and, in
a particularly preferred manner, directly.
[0022] It is advantageous for the container to be acted upon with a
gaseous medium after being filled. Expressed in more precise terms,
a gaseous medium, and in particular nitrogen, is introduced into
the container after the filling procedure. In this way it is
possible for air to be forced out of the head space of the
containers in order to prevent contamination in the head space of
the containers as well in this way.
[0023] In addition, the present invention relates to an apparatus
for producing filled containers, this apparatus having a shaping
device which shapes plastics material pre-forms to form plastics
material containers. In addition, a conveying device is also
provided which conveys the plastics material containers away from
the shaping device and, in addition, a filling device is also
provided which is arranged downstream with respect to the shaping
device along a conveying path of the plastics material containers
and which fills the containers with a liquid. In this case the
filling device is designed in such a way that it fills the liquid
at a temperature of more than 50.degree. C. into the
containers.
[0024] It is advantageous for the apparatus to have a sterilization
device which is arranged between a separating device (for
separating the plastics material pre-forms) arranged upstream of a
pre-form inlet of the shaping device and the filling device and
which sterilizes the containers (10).
[0025] An arrangement between the shaping device and the filling
device is to be understood as being that in this case the
sterilization device can also be arranged in a region of the
shaping device (or in the region of a separating device for
separating the plastics material pre-forms which is optionally
arranged upstream of this shaping device), and for example the
plastics material pre-forms are also sterilized shortly before or
even during the shaping procedure. It is advantageous, however, for
the sterilization device to be arranged downstream of the shaping
device and thus to sterilize the containers already produced.
[0026] In the case of an advantageous embodiment the apparatus has
a application device which is arranged downstream of the filling
device along the conveying path of the plastics material containers
and which acts upon the filled containers with a flowable and
preferably gaseous medium. Expressed in more precise terms, the
liquid present in the containers is acted upon with the gaseous
medium. It is advantageous for the gaseous medium to be nitrogen.
In this case it is possible for this nitrogen also be introduced in
a liquid form.
[0027] As a result of the introduction of this medium, in
particular in a gaseous form, a displacement of the oxygen present
in the filled container or a minimization of the oxygen is made
possible. If the oxygen is introduced in a liquid form, a build-up
of pressure can additionally be achieved in the container, which
build-up of pressure for example counteracts the effect of the
contraction of the liquid present in the container.
[0028] In the case of a further advantageous embodiment the
apparatus has a cooling device arranged downstream of the filling
device for cooling the filled containers. It is preferable for the
cooling device to cool the containers to a temperature which is
between 50.degree. C. and 75.degree. C., preferably between
60.degree. C. and 75.degree. C. and in a particularly preferred
manner between 65.degree. C. and 75.degree. C.
[0029] In this way, the container is no longer so highly stressed
thermally as in the prior art. It is thus also possible for the
container to be produced in a more inexpensive manner, in which
case for example use is made not of a heat setting method but only
of a hot relaxation method. In addition, the weight of the
containers can be significantly reduced. A weight of the containers
as used in aseptic applications has been found to be particularly
suitable, without, on the other hand, the high costs of the
operating expenses of aseptic plants having to be applied.
[0030] An application of the invention is possible both for a
conventional hot filling and for a hot filling with subsequent
stressing with gas (also referred to as NitroHotFill by the
Applicants). In particular, a high degree of efficiency can be
assumed for the last-named method.
[0031] It is advantageous for a closing device for closing the
containers to be arranged upstream of the cooling device. This
means that it is preferable for the containers first to be filled,
then to be closed and finally to be cooled. It is advantageous for
the closing means to be provided substantially immediately
downstream of the application device, which acts upon the liquid
with the gaseous medium.
[0032] In the case of a further advantageous embodiment a sterile
room, through which the container is conveyed, is arranged between
the shaping device and the filling device. The provision of this
sterile room ensures that contamination of the container after the
production thereof can no longer occur. It is advantageous for the
shaping device to be followed substantially directly by the filling
device. It can thus be provided that only one transfer star wheel
is provided as a conveying device between the shaping device and
the filling device. In addition, it would be possible for the
shaping device and the filling device to be arranged in the same
housing. In the case of a further advantageous embodiment the
apparatus has a labelling device which applies a label to the
container. In this case this labelling device is advantageously
arranged downstream of the closing device, which closes the
containers already filled. It is advantageous for the labelling
device also to be provided downstream of the above-mentioned
cooling device for cooling the filled containers.
[0033] A drying device, which dries an outer wall of the
containers, for example by acting upon it with an air flow, can
also be provided between the filling device and the labelling
device. The labelling device can be a labelling device which
applies self-adhesive labels to the containers. Labelling devices
would also be possible however, which apply the labels to the
containers by means of an adhesive, or even those labelling devices
which apply shrink-on labels to the containers.
[0034] Further advantages and embodiments are evident from the
accompanying drawings. In the drawings
[0035] FIG. 1 shows a plant for handling containers from the prior
art, and
[0036] FIG. 2 is a diagrammatic illustration of a plant according
to the invention.
[0037] FIG. 1 is a diagrammatic block diagram of a plant 100
according to the prior art. In this case a shaping device 2, such
as in particular a stretching blow moulding machine, is provided,
which shapes the plastics material pre-forms to form plastics
material containers. For this purpose the plastics material
pre-forms are first conveyed through a heating device 48 such as a
furnace and are then supplied in a heated state to the shaping
device 2. This shaping device 2 is followed by a filling device 4
in which the containers are filled with a beverage. Following this
filling the filled containers are conveyed to a heat exchanger 6 by
way of a conveying path 52, 54 and 56. In this case the reference
number 56 relates to a sterilization unit for a head space of the
containers.
[0038] The heat exchanger 6 is followed in turn by a conveying path
58 for the filled and also closed containers as well as a labelling
device 12 which provides the containers with labels. The reference
number 14 relates to packing devices which for example form groups
from a plurality of containers. Finally, the reference number 16
designates a palletizing means.
[0039] It is clearly evident that the containers filled with the
hot beverage are conveyed away over a relatively long conveying
path (52, 54, 56). In the prior art the hot beverage can act upon
the walls of the containers during this time and these walls can
become unstable as a result
[0040] FIG. 2 is an illustration in the manner of a block diagram
of an apparatus 1 according to the invention. In this case too a
shaping device 2 and a filling device 4 are again provided. The
reference number 5 relates to a conveying device which conveys the
containers from the shaping device [into] the filling device. This
conveying device can be for example a conveyor belt or a
circulating conveyor chain.
[0041] In addition, however, a sterilization device 8, which
sterilizes the shaped containers, is provided additionally between
the shaping device 2 and the filling device 4. As mentioned above,
this can be a sterilization device which acts upon the containers
with gas, for example H.sub.2O.sub.2. It would also be possible,
however, for radiation devices to be used which irradiate the
containers with radiation such as in particular UV radiation,
X-rays or electrons.
[0042] In particular, in this case the inner wall of the containers
is sterilized, but sterilization of the outer wall would also be
additionally possible. The reference number 20 relates to a clean
room which is arranged in the region between the shaping device 2
and the filling device 4. This ensures that the shaped containers
leave this sterile room 20 again in particular only in a closed
state in which contamination is eliminated. The reference number 22
accordingly designates a closing means which closes the filled
containers.
[0043] In this way it would also be possible for the pre-forms to
be already sterilized after entering the furnace in which they are
heated for the blow moulding procedure, or even during the passage
through this furnace. In this way nozzles which act upon the
pre-forms with a sterilizing agent could be arranged for example
above a conveying device for the pre-forms. In addition, the
sterilization devices could also be arranged downstream of the
furnace or between the furnace and the actual blow moulding
stations. It is also possible for the temperature at which the
action of the sterilizing agent is to take place to be indirectly
determined by the arrangement of the sterilization device. In
addition, it would also be possible for a plurality of
sterilization devices to be provided which are arranged for example
at different locations along the conveying path of the containers.
In this case these different sterilization devices could also apply
different methods, for example sterilization by means of UV or
electron radiation and a further sterilization by means of
H.sub.2O.sub.2. In addition, it would also be possible for the
pre-forms to be immersed in a bath with sterilizing agent so that
in this way sterilization of both the inner wall and the outer wall
of the pre-forms is carried out.
[0044] In this way, it is possible for both sterilization of the
pre-forms and sterilization of the plastics material containers
just produced to be carried out. In addition, it is also possible
for the containers to be rinsed with warm water in the course of a
sterilization process. It would also be possible for the outer
areas of the containers to be rinsed by a sterilizing agent being
directed onto an opening of the containers. The interior of the
containers can also be rinsed with (sterile) air after being acted
upon with the sterilizing agent.
[0045] For the purpose of sterilization it is also possible for a
plurality of spray nozzles to be provided which direct the
sterilizing agent onto the surface of the containers. In this case
the jet of the sterilizing medium can be directed for example onto
the lateral faces or the base surface of the containers. It is also
possible for movable spray nozzles to be used. Saturated steam can
also be used for the sterilization. In addition, it is also
possible for sterilization of the surface of the containers to be
achieved by continuously acting upon the latter. The sterilizing
agent can also be heated before the containers are acted upon by
it.
[0046] The filling device is immediately followed in this case by
the cooling device 6 which cools the filled and closed containers.
In this way, the conveying path 52, 54 and 56 illustrated in FIG. 1
is dispensed with. In this case the containers can be conveyed for
example on a belt and preferably arranged adjacent to one another
through this cooling device. In this cooling device the containers
can then be acted upon from the outside with a flowable cooling
agent such as for example water, but optionally also with air. In
addition, a drying device can be further provided which dries the
outer wall of the containers for the purpose of labelling for
example.
[0047] At the same time a stressing device 24, which acts upon the
filled containers with nitrogen for example, can also be provided
in this region.
[0048] The devices downstream of the cooling device 6 once again
correspond essentially to the arrangement shown in FIG. 1. In this
case the reference number 46 relates to a CIP unit for cleaning the
filling device. The reference number 42 designates a pasteurization
unit for pasteurizing the liquid. The reference number 44
designates a mixer which can likewise be used with a multiplicity
of beverages. As a result of the procedure according to the
invention a sterile container arrives in the filling device. On the
conveying path between the shaping device 2 and the filling device
4 it is preferable to ensure that no new contamination enters the
container.
[0049] To this end it is possible for the interior of the container
to be rinsed (in particular with nitrogen). After that, the
container is hot filled at the appropriate filling temperature,
this high filling temperature being necessary--as mentioned
above--in order to keep the filling device sterile. The container
itself is ideally not contaminated itself. The closing device 22 is
preferably provided with a closure disinfection means. In addition,
the container is transferred--as mentioned above--on the shortest
path, in particular by way of a conveyor belt, directly into the
cooling device 6 and it is cooled to a lower temperature there. It
is preferable for the containers to be guided individually upstream
of the heat exchanger in the heat exchanger and in a stream of
containers.
[0050] The Applicants retain the right to claim all the features
disclosed in the application documents as being essential to the
invention, insofar as they are novel either individually or in
combination as compared with the prior art
LIST OF REFERENCES
[0051] 1 apparatus [0052] 2 shaping device [0053] 4 filling device
[0054] 6 heat exchanger [0055] 8 sterilization device [0056] 12
labelling device [0057] 14 packing devices [0058] 16 palletizing
means [0059] 20 clean room [0060] 22 closing means [0061] 24
application device [0062] 42 pasteurization unit [0063] 44 mixer
[0064] 46 CIP unit [0065] 48 heating device [0066] 52, 54, 56
conveying path [0067] 100 apparatus, prior art
* * * * *