U.S. patent application number 13/924327 was filed with the patent office on 2014-12-25 for method and apparatus for hub and spoke aseptic processing.
The applicant listed for this patent is Noble House, LLC. Invention is credited to Scott Eckman, James E. Hurley.
Application Number | 20140377418 13/924327 |
Document ID | / |
Family ID | 52105218 |
Filed Date | 2014-12-25 |
United States Patent
Application |
20140377418 |
Kind Code |
A1 |
Eckman; Scott ; et
al. |
December 25, 2014 |
Method and Apparatus for Hub and Spoke Aseptic Processing
Abstract
Embodiments of hub and spoke aseptic processing system are
disclosed. In one embodiment of the current invention, a spoke
aseptic processing system aseptically unloads an aseptic product
from an aseptic container. The aseptic product is aseptically
transported in the aseptic container from a remote site. One or
more pre-filtered dilution base products are sterilized. The
aseptic product and the sterilized base products are sent to an
aseptic pressurized blending unit to form a final product according
to a predefined formula without breaking sterilization. The final
product is aseptically packaged to a finish product without break
the sterile chain. In other embodiments of the current invention, a
monitor and tracking system is connected with the system to
monitor, track and log aseptic information. The information
collected can be further uploaded to a network connected central
database.
Inventors: |
Eckman; Scott; (St. Charles,
IL) ; Hurley; James E.; (Western Springs,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Noble House, LLC |
Western Springs |
IL |
US |
|
|
Family ID: |
52105218 |
Appl. No.: |
13/924327 |
Filed: |
June 21, 2013 |
Current U.S.
Class: |
426/232 ;
426/392; 53/111R |
Current CPC
Class: |
A23L 2/02 20130101; B65B
55/12 20130101; A23L 2/60 20130101; A23L 2/42 20130101 |
Class at
Publication: |
426/232 ;
53/111.R; 426/392 |
International
Class: |
B65B 55/12 20060101
B65B055/12; B65B 59/00 20060101 B65B059/00 |
Claims
1. A method, comprising: aseptically unloading an aseptic product
from an aseptic container, wherein the aseptic product is
aseptically transported in the aseptic container from a remote
site; sterilizing one or more pre-filtered dilution base products;
blending the aseptic product with one or more sterilized dilution
base products to form a final product according to a formula
without breaking sterilization; and packaging the final product
aseptically without breaking a sterile chain.
2. The method of claim 1, wherein the dilution base products
include water and liquid sweeteners.
3. The method of claim 1, wherein the unloading involves connecting
the aseptic container with a sterilized unloading hose, wherein the
sterilized unloading hose comprises a first opening end connecting
to the aseptic container and a second opening end connecting to a
valve, and wherein the first opening end and the second opening end
have different size.
4. The method of claim 1, wherein aseptically unloading the aseptic
product comprises connecting an aseptic valve to the aseptic
container, and wherein the aseptic valve is either a one-time
aseptic valve or a valve being externally sterilized before
connecting to the aseptic container.
5. The method of claim 1, further comprising: adding aseptic
flavoring doses during the blending process.
6. The method of claim 1, further comprising: checking the aseptic
product to determine whether the sterilization of the compound
aseptic is comprised; and unloading the aseptic product to a backup
sterilizing unit and re-sterilizing the aseptic product if the
sterilization of the aseptic product is compromised.
7. The method of claim 1, further comprising: monitoring and
tracking one or more aseptic information, wherein the aseptic
information comprises: origination hub information, destination
spoke site information, quantity information of the aseptic
product, transportation company and transportation route
information, a bill of laden, a product number from the remote
site, a certificate of analysis from the remote site, a product
specification, product batch information from the remote site, and
formula information of the final product.
8. The method of claim 7, further comprising: sending the tracking
information to a preconfigured aseptic information center.
9. The method of claim 1, further comprising: automatically
metering and controlling a filling volume requirement of one or
more of ingredients according to the formula, wherein the
ingredients comprises: the aseptic product, the dilution base
products and flavoring dosing products.
10. The method of claim 1, wherein the formula can be dynamically
updated.
11. An apparatus, comprising: an aseptic unloading hose, which
connects to an aseptic container and a first valve, wherein the
aseptic container contains an aseptic product that is aseptically
transported from a remote site, one or more sterilization units,
which sterilize one or more pre-filtered dilution base products; an
aseptic pressurized blending unit, which blends the aseptic product
with one or more sterilized dilution base products to form a final
product according to a formula without breaking sterilization; and
an aseptic filling unit, which aseptically fills a plurality of
aseptic packages with the final product without breaking a sterile
chain.
12. The apparatus of claim 11, wherein the dilution base products
include water and liquid sweeteners.
13. The apparatus of claim 11, wherein the aseptic unloading hose
has a first opening end and a second opening end, wherein the first
opening end and the second opening end have different size, and
wherein the second opening is sized to connect to the first
valve.
14. The apparatus of claim 11, further comprising: a second aseptic
valve, which connects to the aseptic pressurized blending unit and
an aseptic flavoring dose source, wherein one or more aseptic
flavoring doses are added to the aseptic pressurized blending
unit.
15. The apparatus of claim 11, further comprising: a backup
sterilization unit, which sterilizes the compound aseptic product
when detecting sterilization of the aseptic product is
compromised.
16. The apparatus of claim 11, further comprising: an unloading
platform upon which the aseptic containers are placed and weighed
before unloading the aseptic product.
17. The apparatus of claim 11, further comprising: an aseptic
pressurized balance unit, which connects to the aseptic pressurized
blending unit and the aseptic filling unit, and wherein the final
product is first received at the aseptic pressurized balance unit
before being sent to the aseptic filling unit.
18. The apparatus of claim 11, further comprising: an aseptic
holding tank that connects to the aseptic container to unload and
to hold the aseptic product before sending the aseptic product for
further processing.
19. The apparatus of claim 11, further comprising: a second
blending unit that aseptically blends aseptic product with one or
more sterilized dilution base products to form the final product
according to the formula without breaking sterilization, wherein
the second blending unit together with the blending unit provide
continuous final product flow to the aseptic filling unit.
20. The apparatus of claim 11, further comprising: a monitor and a
plurality of tracking units, which monitor and track one or more
aseptic information, wherein the aseptic information comprises:
origination hub information, a destination spoke site information,
quantity information of the aseptic product, transportation company
and transportation route information, a bill of laden, a product
number from the remote site, a certificate of analysis from the
remote site, a product specification, product batch information
from the remote site, and formula information of the final
product.
21. The apparatus of claim 11, further comprising: a communication
unit, which sends the aseptic information to a preconfigured
aseptic information center.
22. The apparatus of claim 11, further comprising: a plurality of
automatic meter and control units, which automatically meter and
control a filling volume requirement of one or more of ingredients
according to the formula, wherein the ingredients comprises: the
compound aseptic product, the dilution base products and flavoring
dosing products.
23. The apparatus of claim 11, wherein the formula can be
dynamically changed.
Description
TECHNICAL FIELD
[0001] The disclosed embodiments relate generally to aseptic
processing, and, more particularly, to methods and apparatus for
hub and spoke aseptic processing.
BACKGROUND
[0002] There has been a significant market growth and associated
technical development in the area of aseptic processing.
Traditionally, sterility was achieved through the canning process
by putting the product in a container first and heating the product
and the container together. During the canning process, a lot more
energy is required to heat completely the product inside the
container, resulting in loss of nutrition. In contrast, during
aseptic process the product is heated outside the container in a
continuous, closed system, cooled and then placed into a previously
sterilized container. When a food product is aseptically processed,
it passes through a thin pipe where it is rapidly heated to kill
pathogens before quickly cooled. The short heating time is
sufficient to kill germs while minimizing the quality degradation
to the food nutrition. Further, since the food is filled at ambient
temperatures, containers can be made of different low-cost and
light-weighted materials, such as films and paperboards.
[0003] Despite the many benefits of aseptic processing, the current
aseptic processing system suffers some disadvantages. The current
aseptic processing facilities aseptically process the raw
materials, sterilize the product, and aseptically package the
product. The aseptic plant houses the aseptic processing and
aseptic packaging together or close by. The cost to establish such
a full aseptic plant is quite high. The equipment cost and facility
requirements for a full aseptic processing establishment require a
large amount of initial investment. Such burden hinders further
growth of aseptic processing and limits the flexibility of aseptic
processing.
[0004] The present invention provides a hub-and-spoke system that
significantly reduces the cost of establishing an innovative spoke
aseptic processing facility. An aseptic packaging spoke system is
provided such that aseptic products can be transported from a
remote aseptic hub facility and packaged to final products without
breaking the sterility chain, which starts from the beginning of
the aseptic processing to the end of aseptic packaging. The spoke
aseptic processing system is metered and tracked by an aseptic
information system. The aseptic information system can also be
connected with a centralized information system.
SUMMARY
[0005] Embodiments of hub and spoke aseptic processing system are
disclosed. In one embodiment of the current invention, a spoke
aseptic processing system aseptically unloads an aseptic product
from an aseptic container. The aseptic product is aseptically
transported in the aseptic container from a remote site. One or
more pre-filtered dilution base products are sterilized. The
aseptic product and the sterilized base products are sent to an
aseptic pressurized blending unit to form a final product according
to a predefined formula without breaking sterilization. The final
product is aseptically packaged to a finish product without break
the sterile chain.
[0006] In another embodiment of the current invention, aseptic
flavor doses are aseptically added to the final product without
breaking sterilization. In another embodiment of the current
invention, an aseptic balance tank is used to receive the final
product aseptically from the blending unit before sending the final
product to the filling unit. In one other embodiment of the current
invention, a backup sterilization system is used to re-sterilize
the aseptic product if the system detects that the sterilization is
compromised. In one other embodiment of the current invention, a
second aseptic pressurized blending tank is provided such that the
aseptic filling and packaging unit receives continuous final
product from one of the blending unit. When one of the aseptic
blending unit unloads the entire final product, it restarts to
receive ingredients to produce new batches of final product. At the
same time, the other blending unit would have finished properly
blending all the ingredients and starts to feed the filling unit or
the balance unit so that the system does not need to wait for the
other blending unit to finish blending new final products.
[0007] In other embodiments of the current invention, a monitor and
tracking system is connected with the system to monitor, track and
log aseptic information. A meter and control system is connected
with aseptic spoke system to control and measure the flow rate of
all the ingredients. In one embodiment of the current invention,
the information collected from the monitor and tracking system can
be further uploaded to a network connected central database. The
monitor and tracking system and the meter and control system can be
further connected via a network to a central aseptic center to
receive information from other sites and to update information to
the central aseptic database.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an exemplary diagram of a hub and spoke aseptic
processing system.
[0009] FIG. 2 shows an exemplary block diagram of an aseptic spoke
system.
[0010] FIG. 3 is an exemplary flow chart of an aseptic spoke system
in accordance with embodiments of the current invention.
[0011] FIG. 4 is an exemplary flow chart of a spoke aseptic
processing procedures in accordance with embodiments of the current
invention.
DETAILED DESCRIPTION
[0012] Reference will now be made in detail to some embodiments of
the invention, examples of which are illustrated in the
accompanying drawings.
[0013] FIG. 1 is an exemplary diagram of a hub and spoke aseptic
processing system 100. Hub and spoke system 100 comprises two hub
facilities Hub 101 and Hub 102, and a plurality of spoke facilities
111-115 and 121-125. Hub 101 and Hub 102 are two aseptic hub
facilities. The hub facilities process the raw materials and
sterilize the products. Hub 101 and Hub 102 can have packaging
equipments and produces final products. It can also produce
aseptically processed products stores in large aseptic containers.
These aseptic containers can have either concentrated juices or
single strength juices that are commercially sterile. Hub 101 and
Hub 102 can provide these aseptic products to multiple spoke
facilities for dilution and packaging to final products.
[0014] As shown in FIG. 1, spoke facilities 111, 112, 113, 114 and
115 receive aseptic products from Hub 101. Spoke facilities 115,
121, 122, 123, 124 and 125 receive aseptic products from Hub 102.
Further shown in FIG. 1, one spoke facility can receive aseptic
products from multiple hub facilities. Spoke facility 115 receives
aseptic products from both Hub 101 and Hub 102. The location of
hubs and spokes can be strategically located to serve different
markets. As needs arise, new spoke facilities can be easily added
to serve additional market need because the innovative aseptic
spoke system is easy to setup and costs much less than the
traditional full aseptic plant.
[0015] FIG. 1 further shows a system level overview of an exemplary
hub system 130. Hub system 130 receives raw materials 131 and
processes these raw materials according to predefined process. The
processed product of raw materials 131 was sent to aseptic
processing 132 where the product is aseptically processed. The
aseptic processing 132 includes passing the product in a
continuous, closed system where it is quickly heated and cooled.
The aseptically processed product is then sent to aseptic container
133. The aseptic containers can be any type of aseptic containers,
such as an aseptic tank, an aseptic drum or an aseptic tote. The
aseptic products can be either concentrated juices or single
strength juices that are commercially sterile. For example, aseptic
container 133 can be five-thousand-gallon aseptic tanker and an
unloading valve. Aseptic container 133 can be a fifty-five-gallon
drum with an aseptic bag and an aseptic unloading valve inside.
Aseptic container 133 can be an aseptic tote with an aseptic bag
and an aseptic unloading valve for volumes from two hundred fifty
liters to one thousand liters. Any type of aseptic container 133
can be shipped by available transportation means such as trucks,
trains or ships. The aseptic product in aseptic container 133 can
be transported aseptically to remote places, including across
continents and oceans, without breaking the sterility of the
product in ambient or controlled conditions. Transportation means
134 takes aseptic container 133 and transports the aseptic product
from the hub to other spoke facilities.
[0016] Furthermore, FIG. 1 shows a system level overview of an
exemplary spoke system 140. Transportation 141 aseptically
transports aseptic product from remote facility without breaking
the sterility chain. When spoke system 140 receives aseptic
containers, an aseptic hose is connected to the aseptic valve of
the container (not shown). The aseptic hose is first sterilized
before connecting to the aseptic valve and the spoke system. In one
novel aspect, the aseptic hose is specially designed so that one
end of the opening that connects to the container is of standard
size while the other end that connects to the spoke system 140 is
of a proprietary size. Therefore, the special designed aseptic hose
is required to load the aseptic product from an aseptic container
to spoke system 140. Once the aseptic hose is sterilized and the
valve attached to the container is sterilized, the valve can be
opened to send either the concentrated juices or the single
strength juices to spoke system 140 without breaking sterility.
[0017] Aseptic product 142 unloaded from transportation 141 can be
held in an aseptic holding tank or directly fed into aseptic blend
tank 145. Spoke system 140 has two additional components to
sterilize pre-filtered water and liquid sweetener. Water sterilizer
143 sterilizes pre-filtered water and sends the sterilized water to
aseptic blend tank 145. Sweetener sterilizer 144 sterilizes
pre-filtered liquid sweetener and sends the sterilized liquid
sweetener to aseptic blend tank 145. In one novel aspect, aseptic
product 142, water sterilizer 143, and sweetener sterilizer 144 are
all metered and controlled by a central monitor and track system
151. The ingredients, including the aseptic product, the sterilized
water and the sterilized sweetener are metered by the individual
volume equipments of the finished product according to a predefined
formula.
[0018] Aseptic blend tank 145 is an aseptic pressurized blending
tank to mix properly the ingredients into the final dilution
without breaking sterility. The properly blended final product is
sent to aseptic balance tank 146 where the final product is being
held before sending to the filling equipment. In one novel aspect
of the current invention, there are two aseptic pressurized
blending units such that when one blending unit finishes blending
the product and sending the final product to the aseptic balance
tank, spoke system 140 meters the ingredients into the second
aseptic blending unit. With a second blending unit, aseptic balance
tank 146 can be fed by two blending units alternatively without
waiting for blending process. When the first aseptic blending unit
empties its final product, the second aseptic blending unit would
have finished blending its final product such that it can feed
aseptic balance tank 146 while first aseptic blending unit starts
to take in ingredients or blending the ingredients. Alternatively,
the second aseptic blending unit upon finishing blending can send
the final product to the first aseptic blending unit, which sends
the finished product to aseptic balance tank 146.
[0019] Aseptic balance tank 146 sends the final product to aseptic
filler 147 to packaging the final product to finished products.
Aseptic filler 147 can fill the final product to Bric-Pak (juice
boxes), bags, bottles or any other aseptic packages without
breaking sterility.
[0020] In one novel aspect, spoke system 140 also includes backup
sterilizer 148. Backup sterilizer 148 can re-sterilize aseptic
product 142 when spoke system 140 detects that sterility of aseptic
product 142 might have been compromised. Upon detections of
possible compromise of sterility of aseptic product 142, spoke
system 142, instead of sending it directly to aseptic blend tank
145, sends aseptic product 142 to backup sterilizer 148. Backup
sterilizer 148 takes aseptic product 142, re-sterilizes it and then
sends the re-sterilized aseptic product to aseptic blend tank 145.
For example, spoke system 140 has flow meters in the pipes that
monitor flow rate and pressure of the system. If at any time, the
flow meters detect that the flow rate or pressure from the aseptic
container or from the unloading tank drops below a predefined
threshold level, spoke system 140 will close all valves. The
aseptic product from the container or the unloading tank will be
removed and sent to backup sterilizer 148 to insure sterility.
Other information may also indicate compromise of sterility of the
aseptic product.
[0021] All the ingredients and equipments, including pumps, valves
and tanks in spoke system 140 are metered and controlled by meter
and control system 152. Meter and control system 152 includes flow
meters, valve and pump controllers, and ingredient formula units.
The flow meters measure flow rate and pressure of each components
of spoke system 140. The ingredient formula units control the
components in the spoke system according to a predefined formula or
specification. The predefined formula or specifications can be
dynamically updated through meter and control system 152. The
equipment components and ingredients are also further monitored and
tracked by monitor and track system 151. Monitor and track system
151 collects, monitors and tracks aseptic information about spoke
system 140. Such aseptic information includes an origination hub
information, destination spoke site information, quantity
information of the aseptic product, transportation company and
transportation route information, a bill of laden, a product number
from the remote site, a certificate of analysis from the remote
site, a product specification, product batch information from the
remote site, and formula information of the final product. Monitor
and track system 151 can further take aseptic information from
meter and control system 152, such as flow rate, pressure and other
available information collected. The aseptic information can be
updated manually or automatically. Monitor and track system 151 can
further dynamically adding, deleting or updating entries of aseptic
information being tracked.
[0022] In one novel aspect of the current invention, as further
shown in FIG. 1, hub system 130 and spoke system 140 can be
connected with network 150. Network 150 can connect with multiple
hubs and spokes and maintain a central database that tracks and
logs activities in the whole system. Hub system 130 and spoke
system 140 can upload their collected aseptic information to the
central database through network 150. Hub system 130 and spoke
system 140 can also receive information from the central database
through network 150.
[0023] FIG. 2 shows an exemplary block diagram of an aseptic spoke
system 200. Spoke system 200 receives aseptically transported
aseptic container in transportation unit 201, which transports
aseptic products from a remote site. The aseptic containers in
transportation unit 201 are unloaded to aseptic transfer platform
202. In one embodiment of the current invention, aseptic transfer
platform 202 has a weight scale (not shown) where the unloaded
aseptic totes or aseptic drums can be placed on. The weight scale
of aseptic transfer platform 202 provides the exact weight
information of the product volumes to the system. The information
can be passed to the aseptic information database of aseptic spoke
system 200. When aseptic spoke system 200 receives aseptic products
from an aseptic tanker, the received aseptic products can be
unloaded to aseptic holding tank 203 through valve 265 aseptic hose
210. In one embodiment of the current invention, aseptic hose 210
is sized to connect to the commercially available aseptic tanker,
and differently sized at another end to be the only way to connect
to aseptic spoke system 200. Holding tank 203 holds unloaded
aseptic product and sending the aseptic product to be further
processed in aseptic spoke system 200. Aseptic spoke system 200 can
have multiple holding tanks. In one embodiment of the current
invention, aseptic transfer platform 202 connects to valve 266
through aseptic pump 231. Aseptic transfer platform 202 can send
the aseptic product to aseptic holding tank 203 through valve 266,
which is connected with valve 265. Aseptic loading tank can also
directly send the aseptic product to a blending tank through valve
250, which is connected to valve 266. Aseptic holding tank 203
connects to valve 250 through pump 232. Valve 250 connects to valve
251. Through valve 251, the aseptic products in either aseptic
transfer platform 202 or aseptic holding tank 203 can either be
sent to a blending unit through aseptic pump 245 or be sent to
backup sterilization system 206 when detecting sterility has been
compromised. In one embodiment of the current invention, aseptic
containers, such as aseptic totes or aseptic drums directly
connects to aseptic pump 232 through aseptic hose 210. In one
embodiment of the current invention, the aseptic hose is sized to
connect to the commercially available totes and drums at one end,
and differently sized at another end such that the aseptic hose is
required to connect to aseptic spoke system 200.
[0024] The aseptic product transported aseptically by
transportation 201 from a remote site is received at aseptic spoke
system 200. The aseptic product in different aseptic containers can
be unloaded to aseptic transfer platform 202, which is connected to
one or more blending units, or to aseptic holding tank 203, which
is also connected to the one or more blending units.
[0025] Central control system 280 has two subsystems: monitor and
track subsystem 281 and meter and control subsystem 282. Monitor
and track subsystem 281 and meter and control subsystem 282 can
reside in one single box, or can reside in different computers
while being connected via dedicated physical links or through a
network. Monitor and track subsystem 281 monitors and tracks
aseptic information of aseptic spoke system 200. Meter and control
system 282 measures and controls the flow of aseptic spoke system
200.
[0026] FIG. 2 also shows backup sterilization system 206 that is
connected to aseptic transfer platform 202 and aseptic holding tank
203 through valve 251. Upon detecting sterilization is compromised,
valve 251 is set to send the aseptic products from either aseptic
transfer platform 202 or aseptic holding tank 203 to aseptic pump
233, which sends the aseptic products to backup sterilization
system 206. Backup sterilization system 206 re-sterilizes the
aseptic product and can send the output to a blending unit through
valve 252 through aseptic pump 234.
[0027] Other components of aseptic spoke system 200 include
sterilization system for one or more pre-filtered products, such as
water and liquid sweeteners. Aseptic pump 235 aseptic pumps
pre-filter water to water-sterilization system 204. The sterilized
water is pumped by aseptic pump 236 to be sent to a blending unit
via valve 263. Liquid sweeteners unloaded from transportation 209
through aseptic pump 237. The pre-filtered liquid sweeteners were
pumped into sweetener sterilization system 205 through aseptic pump
237. In one embodiment of the current invention, the sterilized
liquid sweeteners was pumped to aseptic buffer 207 through aseptic
pump 238. The sterilized liquid sweeteners in aseptic buffer 207
can be sent to a blending unit through valve 263 via aseptic pump
239. In one embodiment of the current invention, water
sterilization system 204 uses Reverse Osmosis (RO) and Ultra Violet
(UV) technologies. Liquid sweeteners are heat process to achieve
sterility in Liquid sweetener sterilization system 205.
[0028] In one embodiment of the current invention, aseptic flavor
doses are added to the aseptic final product via aseptic dose
flavor system 208. Aseptic doses can be sent to an aseptic blending
unit through valve 264 via aseptic pump 240.
[0029] All the ingredients are controlled by central control system
280 to be sent to an aseptic blending unit according to a
predefined formula. The aseptic product unloaded from either
aseptic transfer platform 202 or aseptic holding tank 203 is pumped
to an aseptic blending unit via valve 252. Valve 252 also connects
with the output of backup sterilization system 206 when detecting
compromised sterilization. The sterilized pre-filtered base
products, such as water and liquid sweeteners together with aseptic
flavor doses are sent to a blending unit via valve 255. Valve 255
connects to valve 264, which also connects to aseptic pump 240 that
pumps aseptic flavor doses and valve 263. Valve 263 connects to
aseptic pumps 236 and 239, which pumps sterilized water and
sterilized liquid sweeteners, respectively. The aseptic blending
unit receives the right amount of each ingredient and properly
blends them without breaking the sterility chain.
[0030] In one embodiment of the current invention, aseptic spoke
system 200 includes two aseptic blending units: first aseptic
blending unit 211 and second aseptic blending unit 212. The outputs
of first aseptic blending unit 211 and second aseptic blending unit
212 both connects to valve 260, which connects to aseptic pump 244
that pumps the final products to aseptic balance tank 213. The
advantage of having two aseptic blending units is to continuously
feeding aseptic balance tank 213 and aseptic filler 214 such that
the packaging of the finishing product operates continuously
without stopping to wait for one aseptic blending unit while
blending. In one embodiment of the current invention, second
aseptic blending unit 212 can also send its final product to first
aseptic blending unit 211 via valves 259, 256 and 257.
[0031] As exemplary illustrated in FIG. 2, first aseptic blending
unit 211 receives all its ingredients through valve 257. Valve 257
receives aseptic product by connecting to valve 258, which connects
to valve 253. Valve 253, connecting to valve 252, receives aseptic
product either directly from aseptic transfer platform 202 or
aseptic holding tank 203, or from outputs of backup sterilization
system 206. Valve 257 also receives sterilized base products and
aseptic flavor doses by connecting to valve 256, which connects to
valve 255. Valve 255 connects to valve 264, which in one end
connects to receive aseptic flavor doses, and in the other end
connects to valve 263 to receive sterilized dilution base products.
Through valve 257, first aseptic blending unit 211 receives all
ingredients according to a predefined formula and properly blends
them without breaking sterility chain. Once the ingredients are
properly blended, aseptic pump 242 sends the final product to
aseptic balance tank 213 through valves 260 and 261.
[0032] Similarly, second aseptic blending unit 212 receives all its
ingredients through valve 254. Valve 254 receives aseptic product
by connecting to valve 253. Valve 253, connecting to valve 252,
receives aseptic product either directly from aseptic transfer
platform 202 or aseptic holding tank 203, or from outputs of backup
sterilization system 206. Valve 254 also receives sterilized base
products and aseptic flavor doses by connecting to valve 255. Valve
255 connects to valve 264, which in one end connects to receive
aseptic flavor doses, and in the other end connects to valve 263 to
receive sterilized dilution base products. Through valve 254,
second aseptic blending unit 211 receives all ingredients according
to a predefined formula and properly blends them without breaking
sterility chain. Once all ingredients are blended, aseptic pump 241
sends the final product to aseptic balance tank 213 through valves
259, 260 and 261.
[0033] In one embodiment of the current invention, when a single
strength aseptic product is received, the single strength aseptic
product is sent directly to aseptic balance tank 213 without going
an aseptic blending unit. When a single strength aseptic product is
received, valve 253 sends the aseptic product to valve 258, which
opens to valve 261 directly. Valve 261 opens to send the single
strength aseptic product to aseptic balance tank 213 without going
through an aseptic blending unit.
[0034] Aseptic balance tank 213 receives properly blended final
product from an aseptic blending unit or single strength aseptic
product through aseptic pump 244. Valve 262, connecting with
aseptic balance tank 213 meters and controls the final product.
Aseptic pump 243, connecting to aseptic filler 214, pumps final
products from aseptic balance tank 213 to aseptic filler 214.
Aseptic filler 214 fills the aseptic final product into aseptic
packages without breaking the sterility chain.
[0035] In one embodiment of the current invention, flow meters
measure and control the amount of products sending through the
system. The flow rate and amount are also recorded within the
network for documentation and validation. FIG. 2 shows exemplary
flow meters. Flow meter 272 measures and controls the aseptic
product going into aseptic holding tank 203. Flow meter 273
measures and controls the aseptic product going out of aseptic
transfer platform 202. Flow meter 274 measures and controls the
aseptic product going out of aseptic holding tank 203. Flow meter
275 measures and controls the aseptic product going into either of
the aseptic blending tanks. Flow meter 276 and 277 measures and
controls the liquid sweetener going in and out of liquid sweetener
sterilization system 205, respectively. Flow meter 278 measures and
controls water going out of water sterilization system 204. Flow
meter 279 measures and controls aseptic flavor doses going into
either of the aseptic blending tank. Flow meter 280 measures and
controls the aseptic product going out of backup sterilization
system 206. Flow meters 281 and 282 measure and control the aseptic
final product going out of first aseptic blending unit 211 and
second aseptic blending unit 212, respectively. Flow meters 283 and
284 measures and controls the aseptic final product going into
aseptic balance tank 213 and aseptic filler 214, respectively.
[0036] All aseptic valves, aseptic pumps, aseptic flow meters are
connected to central control system 280 and are computer
controlled. Central control system 280 controls the aseptic valves,
aseptic pumps and aseptic flow meters according to a predefined
formula. The predefined formula can be dynamically updated. In one
embodiment of the current invention, central control system 280 is
connected to network 270, which can be connected further to other
information or control systems of different sites.
[0037] FIG. 3 is an exemplary flow chart of an aseptic spoke system
in accordance with embodiments of the current invention. Step 301
determines which blending tank is available. Step 302 receives
aseptic products. The aseptic product is received from an aseptic
container, which is transported from a remote site, such as a
remote aseptic hub plant. Step 303 logs the information of the
received aseptic product. Step 304 determines whether sterilization
is compromised. If step 304 determines that sterilization is
compromised, the process moves to step 311, which updates aseptic
log information and moves to step 312. Step 312 sends the possibly
compromised aseptic product to the backup sterilizer to
re-sterilize the aseptic product. After the product is
re-sterilized in the backup sterilization system, the product is
sent to the pre-determined available aseptic pressurized blending
tank. If step 304 determines that the sterility of the aseptic
product is not compromised, it moves to step 322, which sends the
product to the pre-determined available aseptic pressurized
blending tank. Step 313 sterilizes pre-filter water through the
water sterilization system. The process then moves to step 323,
which sends the sterilized water to the pre-determined available
aseptic pressurized blending tank. Step 314 sterilizes pre-filter
liquid sweeteners through the liquid sweetener sterilization
system. The process then moves to step 324, which sends the
sterilized liquid sweetener to the pre-determined available aseptic
pressurized blending tank. Step 305 determines whether flavors are
needed for the final product according to a predefined formula. If
step 305 determines that one or more flavors are needed, it moves
to step 325. Step 325 sends aseptic flavor doses to the
pre-determined available aseptic pressurized blending tank. Step
326 determines whether a predefined ingredient volume has reached
for each ingredient. If step 326 determines that the predefined
ingredient volume is reached, the process moves to 331, which
blends all received ingredients in the aseptic pressurized blending
unit.
[0038] Once the ingredients are aseptically blended, the process
moves to step 332. Step 332 sends the properly and aseptically
blended final product to the balance unit. Step 333 sends the final
product in the balance tank to the filling unit. Step 334 takes
final product from the filling unit and aseptically packages it to
the finish product without breaking the sterility chain. After
sending the final product to the balance unit, the system moves to
step 335 to determine whether the blending tank is empty by sending
the entire final product to the balance unit. If step 335
determines that the blending tank is empty, it moves to step 336.
Step 336 marks the blending tank as available. The blending tank is
now ready to take in new ingredients.
[0039] FIG. 4 is an exemplary flow chart of a spoke aseptic
processing procedures in accordance with embodiments of the current
invention. Step 401 aseptically unloads an aseptic product from an
aseptic container, wherein the aseptic product is aseptically
transported in the aseptic container from a remote site. Step 402
sterilizes one or more pre-filtered dilution base products. Step
403 blends the aseptic product with one or more sterilized dilution
base products to form a final product according to a predefined
formula without breaking sterilization. Step 404 packages the final
product aseptically without breaking sterile chain.
[0040] Although the present invention has been described in
connection with certain specific embodiments for instructional
purposes, the present invention is not limited thereto.
Accordingly, various modifications, adaptations, and combinations
of various features of the described embodiments can be practiced
without departing from the scope of the invention as set forth in
the claims.
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