U.S. patent application number 15/445154 was filed with the patent office on 2017-06-15 for beverage filling method and apparatus.
This patent application is currently assigned to DAI NIPPON PRINTING CO., LTD.. The applicant listed for this patent is DAI NIPPON PRINTING CO., LTD.. Invention is credited to Atsushi HAYAKAWA, Takaharu HIROOKA, Takaki MAEKAWA, Hitoshi TAKAKU.
Application Number | 20170166342 15/445154 |
Document ID | / |
Family ID | 41340131 |
Filed Date | 2017-06-15 |
United States Patent
Application |
20170166342 |
Kind Code |
A1 |
HAYAKAWA; Atsushi ; et
al. |
June 15, 2017 |
BEVERAGE FILLING METHOD AND APPARATUS
Abstract
Only a bottle properly preliminarily heated is sterilized by
hydrogen peroxide. Temperature inspection to the bottle is
performed while travelling the bottle. During the inspection, a
bottle of which temperature does not reach a predetermined
temperature is removed and a bottle of which temperature reaches
the predetermined temperature is continuously travelled, hydrogen
peroxide condensed mist .alpha. is blown toward a mouth portion 1a
of the bottle by a spray tube 59 disposed at a predetermined
position, and hot air is blown into the bottle from the nozzle
while the nozzle 64 following the mouth portion of the bottle.
According to such operation, only the bottle properly heated can be
sterilized by the hydrogen peroxide, Thereafter, beverage fills the
bottle, which is then sealed.
Inventors: |
HAYAKAWA; Atsushi; (Tokyo,
JP) ; HIROOKA; Takaharu; (Tokyo, JP) ;
MAEKAWA; Takaki; (Tokyo, JP) ; TAKAKU; Hitoshi;
(Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DAI NIPPON PRINTING CO., LTD. |
TOKYO |
|
JP |
|
|
Assignee: |
DAI NIPPON PRINTING CO.,
LTD.
TOKYO
JP
|
Family ID: |
41340131 |
Appl. No.: |
15/445154 |
Filed: |
February 28, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14143707 |
Dec 30, 2013 |
9617136 |
|
|
15445154 |
|
|
|
|
12993727 |
Nov 19, 2010 |
9108835 |
|
|
PCT/JP2009/059183 |
May 19, 2009 |
|
|
|
14143707 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B67C 2003/227 20130101;
A61L 2/186 20130101; B65B 55/103 20130101; B67C 7/0073 20130101;
A61L 2/208 20130101; A61L 2/26 20130101; B67C 3/242 20130101; B65B
55/10 20130101; A61L 2202/23 20130101; B67C 2003/228 20130101; B65B
3/022 20130101 |
International
Class: |
B65B 55/10 20060101
B65B055/10; A61L 2/20 20060101 A61L002/20; B65B 3/02 20060101
B65B003/02; B67C 3/24 20060101 B67C003/24; B67C 7/00 20060101
B67C007/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 20, 2008 |
JP |
2008-131978 |
Dec 26, 2008 |
JP |
2008-334563 |
Feb 6, 2009 |
JP |
2009-026035 |
Feb 6, 2009 |
JP |
2009-026036 |
Feb 17, 2009 |
JP |
2009-033813 |
Claims
1. A beverage filling apparatus comprising: a molding section (7)
for molding a bottle (1) from a heated preform (6) through a blow
molding process; a sterilization section (9) for sterilizing the
bottle (1) molded in the molding section (7) with hydrogen peroxide
mist or hydrogen peroxide gas; a filling section (10) for filling
the bottle (1) sterilized in the sterilization section (9) with
beverage (a) and then sealing the bottle (1), the molding section
(7), the sterilization section (9) and the filling section (10)
being coupled continuously with each other; bottle travelling means
disposed for continuously travelling the bottle (1) on a travelling
path from the molding section to the filling section through the
sterilization section, wherein the bottle travelling means being
provided with wheels (19a, 19b, 36a, 36b, 36c, 58a, 58b, 58c, 58d)
disposed in a row from the molding section. M toward the filling
section (10), characterized in that grippers (28) turn around the
wheels while gripping the bottle neck portion (1a) and transfer the
bottle (1) from an upstream side wheel to a downstream side wheel,
in the sterilization section (9), the bottle (1) is travelled with
the neck portion (1a) directed upward, and a lower end of the spray
tube (59) is opened toward the neck portion (1a) of the bottle (1),
a part of the mist or gas of the hydrogen peroxide supplied into
the spray tube (59) is continuously blown toward the bottle neck
portion (1a) through a nozzle hole formed to the lower end of the
spray tube (59), so that the blown mist or gas of the hydrogen
peroxide flows into the bottle (1) from the neck portion (1a) of
the bottle (1) and sterilizes the inner surface of the bottle (1),
and a remaining part of the mist or gas of the hydrogen peroxide
flows outside of the bottle (1) so as to sterilize the outer
surface of the bottle (1), an air-rinse section (96) for
air-rinsing simultaneously, with aseptic air, the outer and inner
surface of the bottle (1) sterilized in the sterilization section
(9) is further disposed between the sterilization section (9) and
the filling section (10).
2. The beverage filling apparatus according to claim 1, wherein an
aseptic water rinse section (91) for rinsing, with heated aseptic
water, the bottle (1) sterilized in the sterilization section (9)
is further disposed between the air-rinse section (96) and the
filling section (10).
3. The beverage filling apparatus according to claim 2, wherein an
aseptic water rinse section (91) is disposed between the air-rinse
section (96) and the filling section (10), wherein air containing
hydrogen peroxide gas is preferably blown against the bottle (1) in
the air-rinse section (96).
4. The beverage filling apparatus according to claim 1, wherein the
wheels are sectioned into a desired number of rows, each of which
is driven by an independent servo-motor (S1-S2).
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a Divisional of U.S. application Ser. No. 14/143,707
filed Dec. 30, 2013, which is a Divisional of U.S. application Ser.
No. 12/993,727 filed Nov. 19, 2010, which is a National Stage Entry
of International Application No. PCT/JP2009/059183 filed May 19,
2009, which claims priority from Japanese Patent Application No.
2008-131978 filed May 20, 2008, Japanese Patent Application No.
2008-334563 filed Dec. 26, 2008, Japanese Patent Application No.
2009-026035 filed Feb. 6, 2009, Japanese Patent Application No.
2009-026036 filed Feb. 6, 2009, and finally Japanese Patent
Application No. 2009-033813 filed Feb. 17, 2009, the contents of
all of which are incorporated herein by reference in their
entirety.
TECHNICAL FIELD
[0002] The present invention relates to a beverage filling method
for continuously performing processes from bottle molding to
beverage filling through bottle sterilization by hydrogen peroxide,
and also relates to a beverage filling apparatus.
BACKGROUND ART
[0003] As a conventional beverage filling apparatus, there is known
an apparatus provided with a molding section for molding a bottle
from a preform by means of blow molding, a sterilization section
for sterilizing the bottle molded in the molding section by mist of
hydrogen peroxide, air-rinse section for performing air-rinse
treatment to the bottle sterilized in the sterilization section,
and a filling section for filling, with beverage, the bottle
subjected to the air-rinse treatment in the air-rinse section and
then sealing the bottle, these sections being continuously
coupled.
[0004] The apparatus is also provided with drive means for
continuously traveling the bottle from the molding section to the
filling section through the sterilization section and the air-rinse
section, and a portion extending from the molding section to the
filling section is covered by a chamber. According to the beverage
filling apparatus mentioned above, the sterilization effect to the
bottle by the mist of the hydrogen peroxide generated by utilizing
heat added in the bottle molding process (for example, refer to
Patent Publication 1).
[0005] In addition, there is also known an apparatus in which a
bottle molding section and a beverage filling section are coupled
and covered by a clean room, and a sterilization section is
eliminated by supplying a preform in an aseptic state to the
molding section (for example, refer to Patent Publication 2).
[0006] Patent Literature 1: Japanese Patent Laid-open Publication
No. 2006-111295 [0007] Patent Literature 2: Japanese Patent
Laid-open HEI 11-291331.
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0008] The conventional beverage filling apparatus involve the
following problems.
[0009] (1) A process or treatment from the bottle molding process
to the beverage filling process through the bottle sterilization
process by the hydrogen peroxide can be continuously performed.
However, since all the molded bottles are fed to the sterilization
process and the filling process, there is a fear that beverage may
fill even defective bottles, which may be then delivered. For
example, in a case where the bottles heated to an insufficient
temperature are fed to the sterilization process, the sterilization
may be incompletely performed, and such defective bottles are
filled with the beverage and then delivered. In addition, there is
also a fear that damaged bottles filled with the beverage may be
delivered.
[0010] (2) At a time when the bottles are sterilized and filled
with beverage while conveying the bottles, shell portions of the
bottles may be contacted to each other, and because of this reason,
the hydrogen peroxide may insufficiently adhere to the shell
portions of the bottles, which results in defective sterilization
of the bottles or damage may be caused to the bottles.
[0011] (3) In the conventional beverage filling apparatus, the
bottle traveling means is constructed by train or row of wheels
and/or turntables, and for example, if any trouble is caused to the
bottle molding section, all the wheels and the turntables in the
beverage filling apparatus are stopped. However, if all the wheels
and the turntables are stopped in operations, normally molded
bottles stay in the sterilization section, so that the hydrogen
peroxide excessively adheres to the bottles, which may produce
defective bottles. Therefore, if the traveling means is stopped by
any trouble, all the bottles including normal and defective ones in
the beverage filling apparatus will have to be disposed of, thus
providing a problem.
[0012] (4) In the conventional beverage filling apparatus, since
the bottle passes in front of a nozzle through which the hydrogen
peroxide mist is ejected, there may cause a case where the mist
does not spread to every corner portion of the bottle.
Particularly, the mist hardly adheres to the bottom portion inside
the bottle and insufficient sterilization may be performed to this
portion. In order to obviate such defect, in the conventional
technology, a plurality of nozzles is arranged along the bottle
conveying path to eject a large amount of mists. In such
technology, however, a large volume of hydrogen peroxide may be
consumed, thus providing a problem.
[0013] In addition, in a case where the travelling speed for
feeding the bottles is increased for increasing production
efficiency of aseptic packages, it becomes necessary to increase
flow rate of the mist, which will result in further increasing of
the consumption of the hydrogen peroxide. Although this problem may
be considered to be solved by blowing the mist into the bottle
while following the nozzle to the bottle, if the nozzle ejecting
the mist is moved, the mist is liable to be condensed during the
flowing from a mist generating device to the nozzle, and the
condensed hydrogen peroxide may drop on the bottle, thus also
providing a problem.
[0014] Although the condensation may not occur by lowering the
concentration of the hydrogen peroxide, in such case, the
sterilization effect may be degraded, thus also providing a
problem.
[0015] (5) In order to enhance the bottle sterilization effect by
applying the hydrogen peroxide mist, it may be desirable to preheat
the bottle. However, according to a mold for molding the bottle,
there may cause a case where the bottle bottom portion is
excessively cooled, and in such occasion, insufficiently sterilized
bottles may be produced. Such phenomenon is not limited to a case
of utilizing a remaining heat in the molding process and may be
caused in a case where hot air is blown to a pre-molded bottle, or
a bottle is preliminarily heated by approaching a heater to the
bottle.
[0016] (6) In the conventional beverage filling apparatus, mist of
a sterilization agent such as hydrogen peroxide is ejected toward
the bottle. However, in such technology, the mist adheres to
various components or parts of the beverage filling apparatus and
hence corrodes and damages them, thus providing a problem.
[0017] (7) In the conventional beverage filling apparatus, although
the sterilization performance is enhanced by, for example,
utilizing remaining heat in the bottle molding process, heat is
easily removed in contact to a guide or like members of the wheel
during the bottle conveyance, which may deteriorate the
sterilization performance.
[0018] Therefore, an object of the present invention is to provide
a beverage filling method and apparatus capable of solving the
problems encountered in the conventional art mentioned above.
Means for Solving the Problems
[0019] In order to solve the above problems, the present invention
adopts the following structures.
[0020] Further, although the followings are described with
reference numerals on the drawings, the present invention is not
limited thereto.
[0021] In one exemplary embodiment, a beverage filling method
includes: forming a bottle (1) from a heated preform (6) through a
blow molding process; inspecting the bottle (1) after the molding;
blowing hydrogen peroxide mist (.alpha.) or gas (.beta.) to the
bottle (1) within a time in which heat applied to the preform (6)
remains after the inspection; and filling the bottle (1) with
beverage (a) and sealing the bottle.
[0022] In another aspect of a preferred embodiment, it may be
possible that the bottle (1) is subjected to an air rinse treatment
after the blowing of the hydrogen peroxide mist (.alpha.) or gas
(.beta.) to the bottle (1), and the bottle (1) is then filled with
the beverage (a) and sealed.
[0023] In another aspect of a preferred embodiment, it may be
possible that the bottle (1) is subjected to a rinse treatment with
heated aseptic water after the blowing of the hydrogen peroxide
mist or gas into the bottle, and the bottle is then filled with the
beverage and sealed.
[0024] In another aspect of a preferred embodiment, it may be
possible that the bottle (1) is subjected to a rinse treatment with
aseptic water after an air rinse treatment, and the bottle (1) is
then filled with the beverage (a) and sealed.
[0025] In another aspect of a preferred embodiment, it may be
possible that the bottle (1) is subjected to a rinse treatment with
aseptic water after the air rinse treatment with aseptic air
(.gamma.) containing hydrogen peroxide gas (.beta.), and the bottle
(1) is then filled with the beverage (a) and sealed.
[0026] In another aspect of a preferred embodiment, it may be
desired that a travelling path is provided so that the molded
bottle (1) is continuously travelled to a section at which the
sealing of the bottle is performed, the travelling path being
formed from a wheel row (36a and like) around which grippers (28
and like) are arranged, and the bottle (1) is transferred from an
upstream side wheel to a downstream side wheel in a state that a
neck portion (1a) of the bottle (1) is grasped by the gripper (28
and like) around the respective wheels (36a and like) while
revolving.
[0027] In another aspect of a preferred embodiment, it may be
desired that all the steps of molding the bottle (1) from the
heated preform (6) through the blow molding process to the beverage
filling and bottle sealing process is performed while continuously
travelling the bottle (1), after the molding process and before the
sterilization process, a temperature of the bottle (1) to which
heat at the preform heating process remains is inspected, a bottle
(1) of which temperature does not reach a predetermined temperature
is removed, and only a bottle (1) of which temperature reaches the
predetermined temperature is sterilized and filled with the
beverage.
[0028] In another aspect of a preferred embodiment, it may be
possible that the inspection process is performed by inspecting the
bottle temperature and imaging a shell portion of the bottle
(1).
[0029] In another aspect of a preferred embodiment, it may be
possible that the inspection process is performed by inspecting the
bottle temperature and imaging a bottom portion of the bottle
(1).
[0030] In another aspect of a preferred embodiment, it may be
possible that the inspection process is performed by inspecting the
bottle temperature and imaging a top face of a neck portion of the
bottle (1).
[0031] In another aspect of a preferred embodiment, it may be
possible that the inspection process is performed by inspecting the
bottle temperature and imaging a support ring of a neck portion of
the bottle (1).
[0032] Furthermore, an aspect of a preferred embodiment can provide
a beverage filling apparatus comprising: a molding section (7) for
molding a bottle (1) from a heated preform (6) through a blow
molding process; a sterilization section (9) for sterilizing the
bottle (1) molded in the molding section (7) with hydrogen peroxide
mist (.alpha.) or hydrogen peroxide gas (.beta.); and a filling
section (10) for filling the bottle (1) sterilized in the
sterilization section (9) with beverage (a) and then sealing the
bottle (1), in which the molding section, the sterilization section
and the filling section are coupled with each other, bottle
travelling means is disposed for continuously travelling the bottle
(1) on a travelling path from the molding section (7) to the
filling section (10) through the sterilization section (9), and a
portion from the sterilization section (9) to the filling section
(10) is covered by a chamber, wherein an inspection section (8) for
performing a predetermined inspection to the bottle (1) molded in
the molding section (7) is disposed between the molding section (7)
and the sterilization section (9) so as to be coupled therewith,
the inspection section (8) including discharging means (53a and
like) for discharging, from the bottle travelling path, a bottle
judged as a defective bottle by the inspection, and positive
pressure creating means (84 and like) for creating positive
pressure in the inspection section (8) more than pressures in the
molding section (7) and the sterilization section (9), and wherein
the travelling means is provided with wheels (19a and like)
disposed in a row from the molding section (7) toward the filling
section (10) and a gripper (28 and like) turning around the wheels
(19a and like) while gripping the bottle neck portion (1a) and
transferring the bottle (1) from an upstream side wheel to a
downstream side wheel, the gripper being controlled in a travelling
speed such that a heat applied to the preform (6) and remaining to
the bottle (1) is maintained to a temperature necessary for the
sterilization of the bottle in the bottle sterilization section
(9).
[0033] In another aspect of a preferred embodiment, it may be
possible that an air rinse section (96) for air-rinsing, with
aseptic air (.gamma.), the bottle sterilized in the sterilization
section (9) is further disposed between the sterilization section
(9) and the filling section (10).
[0034] In another aspect of a preferred embodiment, it may be
possible that an aseptic water rinse section (91) for rinsing, with
heated aseptic water, the bottle (1) sterilized in the
sterilization section (9) is further disposed between the
sterilization section (9) and the filling section (10).
[0035] In another aspect of a preferred embodiment, it may be
possible that an aseptic water rinse section (91) is disposed
between the air rinse section (96) and the filling section
(10).
[0036] In another aspect of a preferred embodiment, it may be
possible that air (.gamma.) containing hydrogen peroxide gas
(.beta.) is blown against the bottle (1) in the air rinse section
(96).
[0037] In another aspect of a preferred embodiment, it may be
possible that the wheels (36 and like) are sectioned into a desired
number of rows, each of which is driven by an independent
servo-motor (S1 and like).
[0038] In another aspect of a preferred embodiment, it may be
possible that the inspection section (8) is provided with
temperature inspection means (46 and like) for detecting a
temperature of the bottle (1) and judging quality of the bottle
(1).
[0039] In another aspect of a preferred embodiment, it may be
possible that the gripper (28 and like) travelling in the
inspection section (8) is effected with matte surface
treatment.
[0040] In another aspect of a preferred embodiment, it may be
possible that gripper interference prevention means (42 and like)
is provided for preventing interference between grippers (28 and
37) at a time of stopping one of the molding section side wheel
(19b) and the inspection section side wheel (36a) adjacent to the
molding section side wheel (19b).
[0041] In another aspect of a preferred embodiment, it may be
possible that an atmosphere shutoff chamber (79) is disposed
between a chamber (8a) of the inspection section (8) and a chamber
(9a) of the sterilization section (9), clean air is supplied into
the chamber (8a) of the inspection section (8) by air supply means,
and air is discharged from the atmosphere shutoff chamber (79) by
discharge means.
[0042] In another aspect of a preferred embodiment, it may be
possible that the discharge means, for discharging outside the
hydrogen peroxide mist or gas from the chamber (9a) of the
sterilization section (9), is disposed at a portion at which the
chamber (9a) of the sterilization section (9) contacts the
atmosphere shutoff chamber (79).
[0043] In another aspect of a preferred embodiment, it may be
possible that an air nozzle (90) forming an air curtain is disposed
at a portion at which the chamber (9a) of the sterilization section
(9) contacts the atmosphere shutoff chamber (79).
Effects of the Invention
[0044] In an aspect of a preferred embodiment, there is provided a
beverage filling method comprising the steps of: forming a bottle
(1) from a heated preform (6) through a blow molding process;
inspecting the bottle (1) after the molding; blowing hydrogen
peroxide mist (.alpha.) or gas (.beta.) to the bottle (1) within a
time in which heat applied to the preform (6) remains after the
inspection; and filling the bottle (1) with beverage (a) and
sealing the bottle. Accordingly, the beverage (a) can fill only the
bottle (1) which was inspected and judged to be normally molded,
and hence, proper beverage packaging can be provided to a
market.
[0045] In addition, since the hydrogen mist or gas is blown to the
bottle (1) in a time when heat applied to the preform (6) remains,
the bottle (1) can be sterilized by a small amount of the hydrogen
peroxide. In the case of a PET bottle, although adsorbing amount of
the hydrogen peroxide to the bottle wall increases, such adsorption
can be prevented. That is, according to experiment of the
inventors, the density of the hydrogen peroxide condensed to the
surface of the bottle (1) becomes high as high as the temperature
of the bottle (1) because of the fact that the boiling point of the
hydrogen peroxide is higher than that of water. More specifically,
in the case of the bottle temperatures of 50 degrees, 65 degrees,
80 degrees, the density of the hydrogen peroxide adhering to the
surface of the bottle is each approximately 70 weight %, 80 weight
%, 90 weight %. Since the density of the hydrogen peroxide adhering
to the surface of bacteria increases in addition to high
temperature, the bottle (1) can be sterilized by the small amount
of the hydrogen peroxide.
[0046] In another aspect of a preferred embodiment, in the case the
bottle (1) is subjected to an air rinse treatment after the blowing
of the hydrogen peroxide mist (.alpha.) or gas (.beta.) to the
bottle (1), and the bottle (1) is then filled with the beverage (a)
and sealed, even if the bottle (1) is of PET bottle, the remaining
hydrogen peroxide can be properly removed from the bottle (1), and
the following aseptic water rinsing treatment, which requires a
large amount of water and large scale of equipment, can be
eliminated.
[0047] In another aspect of a preferred embodiment, in the case
that the bottle (1) is subjected to a rinse treatment with heated
aseptic water after the blowing of the hydrogen peroxide mist or
gas into the bottle, and the bottle is then filled with the
beverage and sealed, aspergillus spore such as ascomycontina
relatively weak to heat can be sterilized by the aseptic hot water.
Thus, beverage which is liable to be corrupted by the aspergillus
spore can fill the bottle, which is then stored.
[0048] In another aspect of a preferred embodiment, in the case
that the bottle (1) is subjected to a rinse treatment with aseptic
water after an air rinse treatment, and the bottle (1) is then
filled with the beverage (a) and sealed, the hydrogen peroxide
remaining in the bottle (1) can be further reduced.
[0049] In another aspect of a preferred embodiment, in the case
that the bottle (1) is subjected to a rinse treatment with aseptic
water after the air rinse treatment with aseptic air (.gamma.)
containing hydrogen peroxide gas (.beta.), and the bottle (1) is
then filled with the beverage (a) and sealed, the sterilization
effect to the bottle (1) can be further improved, and the hydrogen
peroxide remaining in the bottle (1) can be further reduced.
[0050] In another aspect of a preferred embodiment, in the case
that a travelling path is provided so that the molded bottle (1) is
continuously travelled to a section at which the sealing of the
bottle is performed, the travelling path being formed from a wheel
row (36a and like) around which grippers (28 and like) are
arranged, and the bottle (1) is transferred from an upstream side
wheel to a downstream side wheel in a state that a neck portion
(1a) of the bottle (1) is grasped by the gripper (28 and like)
around the respective wheels (36a and like) while revolving, the
bottle (1) can be smoothly and effectively sterilized by the
hydrogen peroxide within a time when the remaining heat at the time
of heating the preform (6) is not cooled even if the inspection
process is interposed. In addition, the bottle (1) can be fast
conveyed into the air rinse section (96) in a time of the hydrogen
peroxide not adhering to the bottle wall and the hydrogen peroxide
can be prevented from remaining in the bottle (1).
[0051] In another aspect of a preferred embodiment, in the case
that all the steps of molding the bottle (1) from the heated
preform (6) through the blow molding process to the beverage
filling and bottle sealing process is performed while continuously
travelling the bottle (1), after the molding process and before the
sterilization process, a temperature of the bottle (1) to which
heat at the preform heating process remains is inspected, a bottle
(1) of which temperature does not reach a predetermined temperature
is removed, and only a bottle (1) of which temperature reaches the
predetermined temperature is sterilized and filled with the
beverage, only the bottle (1) of which temperature reaches to the
predetermined temperature can contact the hydrogen peroxide mist
.alpha. or gas .beta.. Accordingly, the bottle can be promptly and
surely sterilized, and in addition, the using amount of the
hydrogen peroxide can be reduced. Even if the bottle (1) is made of
PET, which is liable to easily adsorb the hydrogen peroxide, the
remaining of the hydrogen peroxide can be reduced.
[0052] In another aspect of a preferred embodiment, in the case
that the inspection process is performed by inspecting the bottle
temperature and imaging a shell portion of the bottle (1), the
beverage (a) can fill only the bottle (1) which is properly
molded.
[0053] In another aspect of a preferred embodiment, in the case
that the inspection process is performed by inspecting the bottle
temperature and imaging a bottom portion of the bottle (1), the
beverage (a) can fill only the bottle (1) which is properly
molded.
[0054] In another aspect of a preferred embodiment, in the case
that the inspection process is performed by inspecting the bottle
temperature and imaging a top face of a neck portion of the bottle
(1), the causing of defective sealing of the bottle (1) by the
capping can be prevented.
[0055] In another aspect of a preferred embodiment, in the case
that the inspection process is performed by inspecting the bottle
temperature and imaging a support ring of a neck portion of the
bottle (1), the beverage (a) can fill only the normal bottle (1) to
which any burr or injury is formed.
[0056] In another aspect of a preferred embodiment, there is
provided a beverage filling apparatus comprising: a molding section
(7) for molding a bottle (1) from a heated preform (6) through a
blow molding process; a sterilization section (9) for sterilizing
the bottle (1) molded in the molding section (7) with hydrogen
peroxide mist (.alpha.) or hydrogen peroxide gas (.beta.); and a
filling section (10) for filling the bottle (1) sterilized in the
sterilization section (9) with beverage (a) and then sealing the
bottle (1), in which the molding section, the sterilization section
and the filling section are coupled with each other, bottle
travelling means is disposed for continuously travelling the bottle
(1) on a travelling path from the molding section (7) to the
filling section (10) through the sterilization section (9), and a
portion from the sterilization section (9) to the filling section
(10) is covered by a chamber,
[0057] wherein an inspection section (8) for performing a
predetermined inspection to the bottle (1) molded in the molding
section (7) is disposed between the molding section (7) and the
sterilization section (9) so as to be coupled therewith, the
inspection section (8) including discharging means (53a and like)
for discharging, from the bottle travelling path, a bottle judged
as a defective bottle by the inspection, and positive pressure
creating means (84 and like) for creating positive pressure in the
inspection section (8) more than pressures in the molding section
(7) and the sterilization section (9), and
[0058] wherein the travelling means is provided with wheels (19a
and like) disposed in a row from the molding section (7) toward the
filling section (10) and a gripper (28 and like) turning around the
wheels (19a and like) while gripping the bottle neck portion (1a)
and transferring the bottle (1) from an upstream side wheel to a
downstream side wheel, the gripper being controlled in a travelling
speed such that a heat applied to the preform (6) and remaining to
the bottle (1) is maintained to a temperature necessary for the
sterilization of the bottle in the bottle sterilization section
(9).
[0059] Furthermore, the travelling means for conveying the bottle
(1) to the filling section (10) from the molding section (7) is
provided with wheels (19a and like) disposed in a row from the
molding section (7) toward the filling section (10) and a gripper
(28 and like) turning around the wheels (19a and like) while
gripping the bottle neck portion (1a) and transferring the bottle
(1) from an upstream side wheel to a downstream side wheel, the
gripper being controlled in a travelling speed such that a heat
applied to the preform (6) and remaining to the bottle (1) is
maintained to a temperature necessary for the sterilization of the
bottle in the bottle sterilization section (9), and accordingly,
even in the interposing of the inspection section (8), the bottle
(1) can be promptly fed to the sterilization section (9) so as not
to cool the remaining heat at the heating time of the preform (6)
and to suitably sterilize the bottle by the hydrogen peroxide.
Thus, the beverage packaging properly sterilized can be provided to
the market.
[0060] In addition, since the bottle (1) is conveyed by gripping
the bottle neck portion (1a) by the gripper (28 and the like), the
bottles (1) can be prevented from contacting to each other. This
conveying system by using the gripper (28 and like) is lowered in
bio-burden invading into the sterilization section (9) from the
molding section (7) and the sterility assurance level (SAL) of the
product can be improved in comparison with the conventional
conveying system utilizing air. Furthermore, the deformation,
injury, damage and the like can be prevented. Still furthermore, in
the conventional system, it is required to change a screw or guide
used for introducing the bottle into the filling section from the
air conveying path at the time of changing the bottle size, shape
and so on in conformity with the size of the bottle shell portion
and shape, but according to the present invention, such working can
be eliminated. Since the shape and size of the bottle neck portion
is constant regardless of the shape and size of the bottle body, by
adopting the bottle conveying system using the gripper, the screw,
guide and like which are required to be disposed in the
conventional system can be eliminated in location, and the
exchanging working or like working can be also eliminated.
[0061] Furthermore, since the positive pressure creating means (84
and like) for creating the positive pressure in the inspection
section (8) than in the molding section (7) and the sterilization
section (8) is disposed, the invasion of the bacteria and the
hydrogen peroxide into the inspection section (8) can be blocked,
and hence, the inspection equipment or like can be protected from
contamination by the bacteria or corrosion by the hydrogen
peroxide.
[0062] In another aspect of a preferred embodiment, in the case
that an air rinse section (96) for air-rinsing, with aseptic air
(.gamma.), the bottle sterilized in the sterilization section (9)
is further disposed between the sterilization section (9) and the
filling section (10), even if the bottle (1) is made of PET, the
remaining hydrogen peroxide can be completely removed from the
bottle (1) by the air rinsing treatment, thus preventing a large
amount of water from consuming in the following process and also
preventing an aseptic water rinsing treatment requiring a large
equipment from installing.
[0063] In another aspect of a preferred embodiment, in the case
that an aseptic water rinse section (91) for rinsing, with heated
aseptic water, the bottle (1) sterilized in the sterilization
section (9) is further disposed between the sterilization section
(9) and the filling section (10), although it is relatively
difficult to perform the sterilization by the hydrogen peroxide in
the sterilization section (9), aspergillus spore such as
ascomycontina relatively weak to heat can be sterilized by the
heated aseptic water in the aseptic water rinse section (91). Thus,
it is possible to fill the bottle (1) with beverage which is liable
to become corrupted by the aspergillus spore, which is then
stored.
[0064] In another aspect of a preferred embodiment, in the case
that an aseptic water rinse section (91) is disposed between the
air rinse section (96) and the filling section (10), the hydrogen
peroxide remaining in the bottle (1) can be further removed.
[0065] In another aspect of a preferred embodiment, in the case
that air (.gamma.) containing hydrogen peroxide gas (.beta.) is
blown against the bottle (1) in the air rinse section (96), the
sterilization effect to the bottle (1) can be further improved and
the hydrogen peroxide remaining in the bottle (1) can be further
removed.
[0066] In another aspect of a preferred embodiment, in the case
that the wheels (36 and like) are sectioned into a desired number
of rows, each of which is driven by an independent servo-motor (S1
and like), since the wheels arranged in the inspection section (8),
the sterilization section (9), the filling section (10) and so on
are driven by independent servo-motors (S1 and like), respectively,
the respective sections can be synchronously driven.
[0067] In another aspect of a preferred embodiment, in the case
that the inspection section (8) is provided with temperature
inspection means (46 and like) for detecting a temperature of the
bottle (1) and judging quality of the bottle (1), it is possible to
transfer the bottle (1) having a temperature capable of enhancing
the sterilization effect to the sterilization section.
[0068] In another aspect of a preferred embodiment, in the case
that the gripper (28 and like) travelling in the inspection section
(8) is effected with matte surface treatment, the reflection of
right by the gripper or like can be prevented, thus performing the
inspection with high accuracy.
[0069] In another aspect of a preferred embodiment, in the case
that gripper interference prevention means (42 and like) is
provided for preventing interference between grippers (28 and 37)
at a time of stopping one of the molding section side wheel (19b)
and the inspection section side wheel (36a) adjacent to the molding
section side wheel (19b), the damage of the gripper can be
prevented from causing. In addition, the bottle (1) judged to be
normal in the inspection section (8) can be conveyed to the
following sterilization section (9) and filling section (10) by
continuously revolving the wheels, thus preventing the bottles from
wasting. Furthermore, since the bottle (1) can be transferred
without staying in the sections following the sterilization section
(9), a defect such as excessive adhering of the hydrogen peroxide
to the bottle (1) can be prevented from causing. Moreover, since
the bottle (1) inspected in the inspection section (8) reaches the
sterilization section (9) with the remaining heat being maintained,
the sterilization can be suitably performed, thus preventing the
bottle (1) from wasting.
[0070] In another aspect of a preferred embodiment, in the case
that an atmosphere shutoff chamber (79) is disposed between a
chamber (8a) of the inspection section (8) and a chamber (9a) of
the sterilization section (9), clean air is supplied into the
chamber (8a) of the inspection section (8) by air supply means, and
air is discharged from the atmosphere shutoff chamber (79) by
discharge means, the hydrogen peroxide can be prevented from
entering the inspection section (8), thus preventing the equipment
in the inspection section (8) from corroding by the hydrogen
peroxide.
[0071] In another aspect of a preferred embodiment, in the case
that the discharge means, for discharging outside the hydrogen
peroxide mist or gas from the chamber (9a) of the sterilization
section (9), is disposed at a portion at which the chamber (9a) of
the sterilization section (9) contacts the atmosphere shutoff
chamber (79), the hydrogen peroxide flowing into the atmosphere
shutoff chamber (79) can be further reduced, and the equipment in
the inspection section (8) can be appropriately prevented form
corroding by the hydrogen peroxide.
[0072] In another aspect of a preferred embodiment, in the case
that an air nozzle (90) forming an air curtain is disposed at a
portion at which the chamber (9a) of the sterilization section (9)
contacts the atmosphere shutoff chamber (79), the hydrogen peroxide
flowing into the atmosphere shutoff chamber (79) can be further
reduced, and the equipment in the inspection section (8) can be
appropriately prevented form corroding by the hydrogen
peroxide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0073] FIG. 1 is a front view of a bottle as a beverage packaging
material manufactured by a beverage filling apparatus according to
the present invention.
[0074] FIG. 2 is a plan view schematically showing a beverage
filling apparatus according to the first embodiment of the present
invention.
[0075] FIG. 3A is a view representing a supply process of a preform
to the beverage filling apparatus.
[0076] FIG. 3B is a view representing a supply process of the
preform to a molding portion.
[0077] FIG. 3C is a view representing a heating process of the
preform.
[0078] FIG. 3D is a view representing a blow molding process.
[0079] FIG. 3E is a view representing a discharge process for
taking out a bottle from a molding mold.
[0080] FIG. 3F is a view representing a gripping a neck portion of
the bottle by means of gripper.
[0081] FIG. 3G is a view representing a bottle shell inspection
process.
[0082] FIG. 3H is a view representing a bottle temperature
inspection process.
[0083] FIG. 3I is a view representing a bottle support ring
inspection process.
[0084] FIG. 3J is a view representing an inspection process for
inspecting a top face of the neck portion of the bottle.
[0085] FIG. 3K is a view representing a bottle bottom portion
inspection process.
[0086] FIG. 3L is a view representing a bottle sterilization
process by using condensed mist of hydrogen peroxide.
[0087] FIG. 3M is a view representing a bottle air-rinsing
process.
[0088] FIG. 3N is a view representing a beverage filling
process.
[0089] FIG. 3O is a view representing a sealing process by means of
capping.
[0090] FIG. 4 is a plan view schematically showing a gripper,
together with a wheel, for conveying the bottle.
[0091] FIG. 5 is an enlarged view of an inspection portion in FIG.
2.
[0092] FIG. 6 is a view showing a portion arrowed with VI-VI line
in FIG. 5.
[0093] FIG. 7 is a plan view schematically showing a gripper,
together with a wheel, provided with interference prevention
means.
[0094] FIG. 8 is a plan view schematically showing a gripper,
together with a wheel, provided with a defective bottle removing
means.
[0095] FIG. 9A is a side view showing the defective bottle removing
means in a non-operative state.
[0096] FIG. 9B is a side view showing the defective bottle removing
means in an operating state.
[0097] FIG. 10 is a front view of a mist generation device which is
partially cut away.
[0098] FIG. 11 is a front view of an air-rinse device which is
partially cut away.
[0099] FIG. 12 is an explanation view showing positive pressure
creating means and shown from arrowed direction XII-XII in FIGS. 2
and 13.
[0100] FIG. 13 is a plan view representing a beverage filling
apparatus according to a second embodiment of the present
invention.
[0101] FIG. 14A is a view representing an air-rinsing process
performed by the beverage filling apparatus shown in FIG. 13.
[0102] FIG. 14B is a view representing a hot water rinsing process
performed by the beverage filling apparatus shown in FIG. 13.
[0103] FIG. 15A is a plan view showing an opened state of a pair of
clamping pieces of the gripper which inverts the bottle upside
down.
[0104] FIG. 15B is a plan view showing a closed state of a pair of
clamping pieces of the gripper which inverts the bottle upside
down.
[0105] FIG. 16 is partially cutaway view showing a cam device for
turning upside down the gripper shown in FIGS. 15A and 15B.
[0106] FIG. 17 is a plan view of the air-rinse device, partially
cut away, of the beverage filling apparatus shown in FIG. 13.
[0107] FIG. 18 is a schematic plan view, like FIG. 7, representing
another example of the interference prevention means.
[0108] FIG. 19 is a schematic elevational view representing a
further example of the interference prevention means.
[0109] FIG. 20A is a view representing a blow molding process in a
beverage filling method relating to a third embodiment of the
present invention.
[0110] FIG. 20B is a view representing a bottle temperature
inspection process.
[0111] FIG. 20C is a view representing a bottle sterilization
process by means of condensed mist of hydrogen peroxide.
[0112] FIG. 20D is a view representing a bottle air-rinsing
process.
[0113] FIG. 20E is a view representing a bottle hot water rinsing
process.
[0114] FIG. 21 is a schematic plan view representing a beverage
filling apparatus according to a third embodiment of the present
invention.
[0115] FIG. 22 is a schematic plan view representing a beverage
filling apparatus according to a fourth embodiment of the present
invention.
[0116] FIG. 23 is a schematic plan view representing a beverage
filling apparatus according to a fifth embodiment of the present
invention.
EXPLANATION OF REFERENCE NUMERAL
[0117] 1 - - - bottle [0118] 1a - - - neck portion of bottle [0119]
1d - - - top face [0120] 5 - - - support ring [0121] 6 - - -
preform [0122] 7 - - - molding section [0123] 8 - - - inspection
section [0124] 8a, 9a - - - chamber [0125] 9 - - - sterilization
section [0126] 10 - - - filling section [0127] 14a - - - turntable
[0128] 19a, 19b, 36a - - - wheel [0129] 28, 37 - - - gripper [0130]
42 - - - piston ring [0131] 45, 48, 50, 52 - - - camera [0132] 46 -
- - temperature sensor [0133] 53a - - - movable cam [0134] 85 - - -
blower [0135] 79 - - - atmosphere shutoff chamber [0136] 90 - - -
air nozzle [0137] 96 - - - air-rinse section [0138] 97 - - - heater
[0139] a - - - beverage [0140] w - - - hot water [0141] .alpha. - -
- hydrogen peroxide condensed mist [0142] .beta. - - - hydrogen
peroxide gas [0143] .gamma. - - - aseptic hot air [0144] S1 - - -
servo-motor
BEST MODE FOR CARRYING OUT THE INVENTION
[0145] Hereunder, exemplary modes for embodying the present
invention will be described.
First Embodiment 1
[0146] First, a beverage packaging body manufactured by a beverage
filling apparatus of the present invention will be described. The
beverage packaging body is provided, as shown in FIG. 1, with a
bottle 1 as a container and a cap 2 as a lid. In FIG. 1, a letter
"a" denotes a beverage filling the bottle 1.
[0147] The bottle 1 has a shell portion substantially in a
circularly cylindrical shape, but another cylindrical shape may be
adopted. A bottom portion of the shell portion is closed and a neck
portion 1a having a circular opening is formed to an upper portion
of the shell portion.
[0148] The neck portion 1a of the bottle 1 is formed with a male
threaded portion 3 and, on the other hand, a female threaded
portion 4 is formed to the cap 2. When these male and female
threaded portions 3 and 4 are screw-engaged, the opening of the
neck portion 1a of the bottle 1 is sealed. Furthermore, the neck
portion 1a of the bottle 1 is provided with a support ring 5 below
the male threaded portion 4, and as mentioned hereinafter, the
bottle 1 is held by the gripper through the support ring 5 and
travelled in the beverage filling apparatus.
[0149] The bottle 1 is formed by blow-molding a PET preform 6
having an approximately test tube as mentioned hereinafter.
However, the bottle 1 may be formed from a resin material such as
polypropylene or polyethylene other than the PET. The preform 6 is
molded through an injection molding process or like and is provided
with a test tube shaped body portion and a neck portion 1a like
that of the bottle 1. This neck portion 1a is formed with the male
threaded portion at the same time of the formation of the preform
6.
[0150] The cap 2 is formed of a resin such as polyethylene or
polypropylene through the injection molding process, and the female
threaded portion 4 is also formed at the same time of the molding
of the cap 2.
[0151] The beverage filling apparatus for filling the bottle 1 with
beverage "a" will be explained hereunder.
[0152] As shown in FIG. 2, this beverage filling apparatus is
provided with a molding section 1 for molding the bottle 1, an
inspection section 8 for inspecting the molded bottle 1, a
sterilization section 9 for sterilizing the bottle 1, an air-rinse
section 96 for air-rinsing the bottle 1, and a beverage filling
section 10 for filling the bottle 1 with the beverage "a" and
sealing the same.
[0153] The bottle molding section 7 is entirely covered with a
chamber 7a, which is provided with a supply port for the preform 6
and a discharge port for the bottle 1.
[0154] A preform supply machine 11 is installed near the chamber 7a
of the molding section 7. A plurality of preforms 6, each shown in
FIG. 3A, is charged into the preform supply machine 11. The preform
supply machine 11 serves to supply the preforms 6 one by one by a
preform conveyer 12 into the molding section 7 through the supply
port in a standing attitude with the neck portion 1a directed
upward as shown in FIG. 3A.
[0155] Since the preform supply machine is per-se known machine,
details thereof are omitted herein.
[0156] As shown in FIG. 2, within the chamber 7a of the molding
section 7, there are arranged an upstream side wheel row, a
downstream side wheel row, and a turntable row disposed between the
upstream side and downstream side wheel rows.
[0157] The upstream side wheel row includes a stating end wheel
13a, as a horizontal wheel, connected to the preform conveyer 12. A
plurality of grippers, not shown, for gripping the neck portions 1a
of the preforms 6 are arranged at a constant pitch around the
starting end wheel 13a. These grippers are rotated in accordance
with the rotation of the starting end wheel 13a, and each of the
preforms 6 supplied from the preform conveyer 12 is gripped at a
portion near the support ring 5 by the gripper and is then conveyed
to an intermediate wheel 13b.
[0158] The intermediate wheel 13b is arranged in a standing
attitude, and a number of forks, not shown, are disposed at a
constant pitch around the intermediate wheel 13b. This intermediate
wheel 13b serves to rotate the preform 6 in an inverted state by
rotating upward the preform after receiving the preform in a manner
such that the forks of the intermediate wheel 13b clamp the preform
6 gripped by the gripper of the starting end wheel 13a at a portion
lower than the support ring 5. The final end wheel 13c is a
horizontal wheel having a gripper as like as the starting end wheel
13a, and the preform 6 inverted by the intermediate wheel 13b is
gripped and received by the gripper.
[0159] The row of the turntables includes annularly arranged six
turntables 14a, 14b, 14c, 14d, 14e and 14f, between which an
endless chain 15 is stretched. The endless chain 15 extends and
forms a circular path around the third turntable 14c. Such extended
circular portion of the chain 15 travels in the heating chamber 16
disposed inside the chamber 7a. This chain 15 continuously runs in
one direction shown with an arrow in FIG. 2 together with the first
to six turntables 14a, 14b, 14c, 14d, 14e and 14f.
[0160] A number of mandrels 17 are coupled with the chain 15 at
constant pitch as shown in FIG. 3B. The mandrel 17 may travel in an
inverted attitude on the turntables 14a to 14f while being pulled
by the chain 15. Further, the mandrel 17 is supported on the chain
15 to be rotatable around its axis.
[0161] The first turntable 14a is coupled with the final end wheel
13c in the upstream side wheel row, and the mandrel 17 enters, as
shown in FIG. 3B, the neck portion of the inverted preform 6 held
by the gripper of the final end wheel 13c and then receives the
preform 6.
[0162] As shown in FIG. 3C, a heater 16a is mounted on a wall
surface of the heating chamber 16. The mandrel 17 receiving the
preform 6 travels along the heater 16a in the heating chamber 16,
and the preform 6 held by the mandrel 17 is heated by the heater
16a as shown in FIG. 3C. According to this heating, the temperature
of the preform 6 increases to a temperature by which the blow
molding can be performed. The respective mandrels 17 revolve
together with the preforms 6 during their running by the contact of
flanged portions thereof to rails, not shown. Therefore, a portion
of the preform 6 lower than the neck portion 1a thereof is heated
more uniformly.
[0163] Around the fifth turntable 14e, a number of blow molding
molds 18 are disposed at constant pitch. The blow molding molds 18
are rotatable in accordance with the rotation of the fifth
turntable 14e.
[0164] The blow molding mold 18 is splittable into a lateral pair
of halves, and when the heated preform 6 is transferred from the
fourth turntable 14d, the split blow molding mold halves camp the
preform 6 together with the mandrel 17 as shown in FIG. 3D while
rotating around the fifth turntable 14e. A through hole is formed
at the central portion of the mandrel 17, and a blow nozzle 19 is
inserted into this through hole toward the preform 6. Then, the
bottle 1 is molded inside the mold 18 by blowing gas such as air
into the preform 6 from the blow nozzle 19.
[0165] The splittable blow molding mold 18 is opened when
approaching the sixth turntable 14f to thereby release the bottle
1. The bottle 1 released from the blow molding mold 18 is fed to
the first turntable 14a through the sixth turntable 14f in a state
being held by the mandrel 17 as shown in FIG. 3E.
[0166] The starting end wheel 19a in the downstream side wheel row
is connected to the first turntable 14a mentioned above, and the
final end wheel 19b contacts a discharge port of the chamber 7a of
the molding portion 7.
[0167] When the bottle 1 held by the mandrel 17 reaches as shown in
FIG. 3E by the rotation of the first turntable 4a, the starting end
wheel 19a grips the bottle 1 by the gripper 90 as shown in FIG. 3F
and pulls off the bottle from the mandrel 17, and thereafter, the
bottle 1 is inverted vertically so as to take a normal standing
attitude.
[0168] The final end wheel 19b has a gripper 28 as shown in FIG. 4.
This gripper 28 is provided with a pair of clamp pieces 28a, 28b
claming the neck portion 1a of the bottle 1 from the outer side
thereof. The paired clamp pieces 28a and 28b are formed with base
portions, respectively, which are supported by vertical pins to be
rotatable. Further, a pair of gears 30a, 30b which are engageable
with each other are fixed to the base portions through the vertical
pins. In addition, one of the gears 30b is coupled with a cam
follower 31a through a lever 31, and the other one of the gears 30a
is coupled with the wheel 19b through a lever 32 and a spring 33.
According to pulling force of the spring 33, a pair of clamp pieces
30a and 30b are always urged in a direction to be opened. Further,
a cam 34 to which the cam follower is contacted is fixed to a
frame, not shown, inside the wheel 19b.
[0169] Accordingly, when the wheel 19 is rotated, the gripper 28
serves to open the paired clamp pieces 28a and 28b through the
sliding motion between the cam follower 31a and the cam 34 to
thereby receive and then clamp the neck portion 1a of the bottle 1
from the gripper 28, and then the gripper 1 is turned toward the
next inspection section 8 while maintaining the suspended state of
the bottle 1. When the gripper 28 reaches to the inspection section
8, the paired clamp pieces 28a and 28b are opened by the sliding
motion between the cam follower 31a and the cam 34 and transfer the
bottle 1 to the wheel row on the inspection section side.
[0170] When the gripper 28 of the final end wheel 19b receives the
bottle 1 from the gripping member 98 of the start end wheel 19a,
the gripper 28 grips the bottle 1 at a portion below the support
ring 5 of the neck portion 1a of the bottle 1 as shown in FIG. 6,
and the bottle 1 is conveyed in this state.
[0171] As shown in FIG. 2, the bottle inspection section 8 is
connected to the bottle molding section 7. This inspection section
8 is entirely covered by the chamber 8a. As shown in FIG. 12, a
bottle passing port 35a is formed to the partition wall 35 disposed
between the molding section 7 and the chamber 7a thereof.
[0172] As shown in FIG. 2, the wheel row to be coupled with the
final end wheel 19b as a travelling means of the bottle 1 on the
molding section side is connected to the inside of the chamber 8a
of the inspection section 8. More specifically, this wheel row
includes three wheels 36a, 36b 36c, and a bottle travelling path is
set to the outer peripheries of these wheels. Further, grippers 28
having the same structure of the gripper 28 of the final end wheel
19b is disposed around to each of these three wheels 36a, 36b and
36c. These grippers 28 grip the neck portions 1a of the bottles 1
around the wheels 36a, 36b and 36c, respectively, and then turn
around, and during this motion, the bottle 1 is transferred to the
final end wheel 36c from the start end wheel 36a through the
intermediate wheel 36b. Thus, the bottles 1 continuously travel on
the travelling path around the wheels 36a, 36b and 36c in the
inspection section 8 from the final end wheel 19b in the molding
section 7. During this travelling, since the clamp pieces 28a and
28b clamp the neck portion 1a of the bottle 1, the bottle 1 is
conveyed in the suspended state. As shown in FIG. 6, the gripper 28
grips the neck portion 1a of the bottle 1 at a portion above the
support ring 5 at the start end wheel 36a, grips the neck portion
1a of the bottle 1 at a portion below the support ring 5 at the
intermediate wheel 36b, and grips the neck portion 1a of the bottle
1 at a portion above the support ring 5 at the final end wheel 36c,
and in this manner, the bottle 1 is conveyed in the inspection
section 8 from the upstream side toward the downstream side.
[0173] Gripper interference preventing means is disposed to the
start end wheel 36a in the inspection section 8 contacting to the
final end wheel 19b on the bottle molding section 7 side for the
purpose of preventing interference between the gripper 28 mounted
to the final end wheel 19b on the molding section side and the
gripper 28 of the start end wheel 36a of the inspection section
side at a time when the turntable or wheel on the bottle molding
section side is emergently stopped.
[0174] As shown in FIG. 7, a gripper 37 of the start end wheel 36a
in the inspection section 8 has a structure different from the
gripper 28 because of the provision of the gripper interference
preventing means.
[0175] That is, as shown in FIG. 7, a plurality of grippers 37 are
mounted to the start end wheel 36a in the inspection section 8 at a
predetermined pitch, and each of the grippers 37 has a pair of
clamp pieces 37a and 37b for clamping the neck portion 1a of the
bottle 1 from the outer side thereof, and base portions of the
paired clamp pieces 37a, 37b are supported to be pivotal to the
wheel 36a by means of vertical pins, respectively, and a pair of
mesh gears 38a and 38b are fixed to the base portions of these
clamp pieces 37am 37a by means of vertical pins.
[0176] Furthermore, a cam follower 39a is coupled with one of the
gears 38a through one end of a lever 39, and one of the clamp
pieces 37a is coupled with the other end of the lever 39 opposing
to the cam follower 39a through a pin 40a and a circular-arc-shaped
slot 40b. On the other hand, the other clamp piece 37b is formed
integrally with the other gear 38b, and the clamp piece 37b is
coupled with a piston rod 42a of a piston-cylinder assembly 42
through a pin 41a and a circular-arc-shaped slot 41b. The
piston-cylinder assembly 42 is supported by the wheel 36a.
[0177] A torsion spring, not shown, is disposed between the gears
38a, 38b and the wheel 36a, and a pair of clamp pieces 37a and 37b
is always urged in the closing direction by the twisting force of
the torsion spring. Further, the cam follower 39a is also always
pushed against the cam 43.
[0178] According to the structure or arrangement mentioned above,
when the start end wheel on the inspection side is rotated, the
gripper 37 opens the paired clamp pieces 37a and 37b and receives
the neck portion 1a of the bottle 1 from the gripper 28 of the
final end wheel on the molding section side. Thereafter, the neck
portion 1a of the bottle 1 is clamped and turned with the bottle 1
being maintained in its suspended state. The clamp pieces 37a and
37b are rotated in the opening direction against the twisting force
of the torsion spring, and in this instance, the respective pins
40a and 41a are slid in the circular-arc-shaped slits 40b and 41b,
respectively.
[0179] By the way, there may be caused a case where some
abnormality is caused on the side of the molding section 7, and the
turntable row or wheel row is emergently stopped. In such occasion,
as shown in FIG. 7, the piston rod 42a of the piston-cylinder
assembly 42 is contracted, thereby widening the closed paired clamp
pieces 37a and 37b to about 180 degrees opened position.
Accordingly, the interference between the gripper 28 mounted to the
final end wheel 19b on the molding section side and the gripper 37
mounted to the start end wheel 36a can be prevented from causing.
In this case, the start end wheel 36a and the subsequent wheel row
of the wheel 36b are being rotated, so that the bottle 1 introduced
into the inspection section 8 is continuously travelled toward the
downstream side.
[0180] Further, the gripper interference preventing means is not
limited to the structure mentioned above, and as shown in FIG. 18,
there may be adopted a slide structure in which the gripper 37 is
reciprocally slid in the radial direction of the wheel 36a. In FIG.
18, reference numeral 99 denotes a holding member holding the
gripper 37, and a piston rod 100a of a piston-cylinder assembly 100
is connected to the holding member 99. The piston-cylinder assembly
100 is fixed to the wheel 36a along the radial direction
thereof.
[0181] In an occasion in which when any abnormal event is generated
on the molding section side and the turntable row and the wheel row
on the molding section side are emergently stopped, as shown in
FIG. 18, the piston rod 100a of the piston-cylinder assembly 100 is
contracted and the gripper 37, which protrudes outward in the
radial direction of the wheel 36a, is pulled inward in the radial
direction. According to such motion, the interference between the
gripper 28 mounted to the final end side wheel 19b on the molding
section side and the gripper 37 of the start end wheel 36a on the
inspection section side can be prevented.
[0182] Further, for the gripper interference preventing means shown
in FIG. 18, when the piston rod 100a is contracted, the cam 43
operating for opening or closing the paired clamp pieces 37a, 37b
of the gripper 37 is moved in the axial direction of the wheel 36a
by an actuation of another piston-cylinder assembly, for example,
and accordingly, the cam 43 is moved so as to escape to a position
not abutting against the cam follower 39a.
[0183] Further, as the gripper interference preventing means, as
shown in FIG. 19, a rotating mechanism for rotating the gripper 37
in the vertical direction of the wheel 36a may be employed. The
gripper 37 is coupled with a hinge 101 to be rotatable in the
vertical direction with respect to the wheel 36a and is then
coupled with a wheel 103 which is integrally rotatable with the
wheel 36a through a piston-cylinder assembly 102.
[0184] In an occasion in which when any abnormal event is generated
on the molding section side and the turntable row and the wheel row
on the molding section side are emergently stopped, as shown in
FIG. 22, the piston rod 102a of the piston-cylinder assembly 102 is
expanded and the gripper 37, which protrudes outward in the radial
direction of the wheel 36a, is rotated downward as the hinge 101
being a fulcrum point. According to this motion, the interference
between the gripper 28 mounted to the final end side wheel 19b on
the molding section side and the gripper 37 of the start end wheel
36a on the inspection section side can be prevented. Further, in
FIG. 19, reference numeral 104 denotes a machine table supporting a
swivelling shaft 105 of the wheels 36a and 103.
[0185] Further, in the embodiment described above, the structure in
which the gripper 37 is pivoted downward was employed, a structure
in which the gripper is pivoted upward may be employed.
[0186] As shown in FIG. 3G and FIG. 5, a lamp 44 as lighting means
and a camera 45 as imaging pick-up means are disposed at
predetermined positions around the start end wheel 36a in the
chamber 8a of the inspection section 8, and the lamp 44 and the
camera 45 are arranged as bottle shell portion inspection means
discriminating the quality of the bottle by imaging a circular or
rectangular cylindrical shell portion of the bottle 1.
[0187] Irradiation light from the lamp 44 penetrates the shell
portion of the bottle 1 and the camera 45 receives the irradiation
light and then images the bottle 1. The pick-up image of the shell
portion of the bottle 1 is processed by an image processing device,
not shown, so as to discriminate whether any abnormality such as
injury, foreign material, discoloration or like is caused or
not.
[0188] As shown in FIGS. 3H, 3I, 3J and 3K, and FIG. 5, a
temperature sensor 46, a lamp 47 and a camera 48, a lamp 49 and a
camera 50, and a lamp 51 and a camera 52 are arranged in the
described order along the intermediate wheel 36b disposed in
adjacent to the start end wheel 36a. The temperature sensor 46
constitutes temperature inspection means which detects a
temperature of the bottle 1 and discriminates the quality of the
bottle 1. The lamp 47 as lighting means and the camera 48 as
imaging means constitute support ring inspection means which images
the support ring 5 of the neck portion 1a of the bottle 1 and
discriminates the quality of the bottle 1. The lamp 49 as lighting
means and the camera 50 as imaging means constitute bottle neck
portion upper face inspection means which images the flat and
smooth ring-shaped face of the neck portion 1a of the bottle 1 and
discriminates the quality of the bottle 1. The lamp 51 as lighting
means and the camera 52 as bottle bottom portion inspection means
which images the bottom portion of the bottle 1 and discriminates
the quality of the bottle 1.
[0189] The respective means mentioned above may be altered in the
arrangement order and in the positions, or may be optionally
eliminated in location, or another inspection means may be
optionally added.
[0190] The temperature sensor 46 is, for example, an infrared
radiation thermometer, but another thermometer may be employed. The
temperature sensors 46 are disposed so as to oppose to the support
ring 5 of the neck portion 1a of the bottle 1 and the bottom
portion thereof, respectively, as shown in FIG. 3H.
[0191] The bottle 1 travels around the start end wheel 36a and the
intermediate wheel 36b at a predetermined speed while maintaining
the remaining heat at the molding section 7 and being gripped by
the gripper 28, and the temperature of the bottle surface is
detected during this travelling. The remaining heat of the bottle 1
is necessary for appropriately sterilizing the bottle 1 with
hydrogen peroxide in the latter stage, and it is desirable that the
temperature of the bottle surface to be detected by the temperature
sensor 46 is more than 50.degree. C.
[0192] In the temperature detection mentioned above, when at least
either one of the temperatures detected by two portions of the
bottle 1 by two temperature sensors 46 does not reach the
predetermined temperature, it is discriminated that the detected
bottle 1 is defective one. That is, the bottle 1 of which
temperature does not reach the predetermined temperature may have
possibility of being insufficiently sterilized even by the hydrogen
peroxide sterilization in the latter stage. On the contrary, the
bottle 1 of which temperature reaches the predetermined temperature
can be sufficiently sterilized by the hydrogen peroxide
sterilization performed in the latter stage.
[0193] The two portions of the bottle 1 of which temperatures are
to be detected are portions having thick resin thickness and which
are liable to cause cold spots. However, the temperature sensors 46
may be arranged to portions other than the two portions mentioned
above, and the locating number may be changed in accordance with
the shape and size of the bottle 1, the kind of the molding
(injection) mold or like. For example, the temperature sensor 46
may be disposed only to the portion opposing to the bottom portion
of the bottle 1 at which a cold spot is liable to be caused.
[0194] Furthermore, since the heat of the thin portion of the
bottle 1 is liable to escape in comparison with the thickened
portion thereof, the temperature sensor 46 may be disposed so as to
oppose to the thin thickness shell portion of the bottle 1.
According to this arrangement, only the bottle 1 maintaining the
remaining heat minimally necessary for the sterilization of the
bottle in the latter stage may be transferred to the sterilization
section 9.
[0195] As shown in FIG. 3I and FIG. 5, the lamp 47 as the support
ring inspection means is annularly disposed above the support ring
5 of the neck portion 1a of the bottle 1. More specifically, the
lamp 47 is composed of LED (light emitting diode) disposed
annularly. The camera 48 is arranged so as to receive the light of
the lamp 47 reflected by the upper surface of the support ring 5,
thus the support ring 5 being imaged. At this time, since the clamp
pieces 28a, 28b of the gripper 28 grip the neck portion 1a at the
lower portion of the support ring 5, as shown in FIG. 6, the
imaging operation to the support ring 5 cannot be obstructed by the
clamp pieces 28a, 28b of the gripper 28. The upper surface
condition of the support ring 5 is specifically inspected by this
support ring inspection means.
[0196] The image of the support ring 5 picked up by the camera 48
is processed by the image processing device, not shown, and it is
discriminated whether any abnormality such as injury, deformation
or like may be exist. caused, Because the support ring 5 may be
contacted or touched by a customer who obtains the bottle 1 as a
beverage bottle when the cap thereof is opened, the existence of
any injury or deformation is not desirable, and a bottle 1 having
injury or deformation of an extent beyond allowance is judged as
defective product.
[0197] As shown in FIG. 3J and FIG. 5, the lamp 49 as the bottle
neck portion upper face inspection means is annularly arranged
above the upper (top) face 1d of the bottle neck portion 1a. More
specifically, the lamp 49 is composed of LED (light emitting diode)
disposed annularly. The camera 50 is arranged so as to receive the
light of the lamp 49 reflected by the upper face 1d of the support
ring 5, thus the upper face 1d of the support ring 5 being imaged.
The image of the upper face 1d picked up by the camera 50 is
processed by the image processing device, not shown, and existence
of abnormality such as injury, deformation or like is
discriminated. The upper face 1d of the bottle neck portion 1a is a
portion for sealing the interior of the bottle 1 in contact of this
upper face 1d of the bottle neck portion 1a to the ceiling portion
of the cap 2 (see FIG. 1), so that the upper face 1d of the bottle
neck portion 1a is required to be flat and smooth. Because of this
reason, a bottle 1 detected to have injury or deformation is judged
to be a defective product.
[0198] As shown in FIG. 3K and FIG. 5, the lamp 51 as the bottle
bottom portion inspection means is annularly arranged below the
bottom portion of the bottle 1. More specifically, the lamp 49 is
composed of LED (light emitting diode) disposed annularly. The
camera 52 is arranged so as to receive the light of the lamp 49
passing through the bottom portion of the bottle 1, thus the bottom
portion of the bottle 1 being imaged. The image of the bottom
portion of the bottle 1 picked up by the camera 52 is processed by
the image processing device, not shown, and existence of
abnormality such as injury, deformation or like is
discriminated.
[0199] Further, although not shown, the gripper 28 travelling
inside the inspection section 8 is effected with a matte surface
working. According to this surface working, inspection miss due to
reflection of irradiation light from the respective lamps 47, 49
and 51 to the gripper 28 can be prevented from causing. In
addition, a peeping (inspection) hole, not shown, is formed to the
chamber 8a of the inspection section 8, and a muffled glass is
fitted to the peeping hole so that outside light is prevented from
entering inside the chamber 8a.
[0200] The final end wheel 36c contacting the intermediate wheel
36c from the downstream side thereof is provided, as shown in FIG.
8, with a gripper 28 of the structure similar to the gripper 28 of
the intermediate wheel 36b. When the final end wheel 36c is
rotated, due to the slide-contact function between the cam follower
31a and the cam 53, the gripper 28 opens the paired clamping pieces
28a, 28b so as to clamp the bottle neck portion 1a after receiving
the neck portion 1a of the bottle 1 from the gripper 28 of the
intermediate wheel 36b, and then, swivels bottle 1 to the
subsequent sterilization section 9 while holding the bottle in the
suspended attitude. When the gripper 28 reaches the sterilization
section 9, the paired clamp pieces 28a, 28b are opened by the
slide-contact function between the cam follower 31a and the cam 53,
and then, the bottle 1 is transferred to the wheel on the
sterilization section side. The cam 53 is fixed to a stationary
frame, not shown, disposed inside the final end wheel 36c.
[0201] The final end wheel 36c is provided with discharge means for
discharging the bottle 1, which was judged as defective product by
the inspection in the inspection section 8, from the bottle
travelling path.
[0202] The discharge means has a gripper releasing mechanism such
as shown in FIGS. 8 and 9. The gripper releasing mechanism includes
an additional cam follower 31b further added to the pivot shaft 54
of the cam follower 31a and having a shape similar to the cam
follower 31a, and another additional cam follower 55 contacting the
additional cam follower 31b and being different partially in shape,
the additional cam follower 55 being disposed below the cam 53.
Furthermore, the gripper releasing mechanism further includes a
movable cam 53a as one portion separated from the cam 53 to be
movable.
[0203] The movable cam 53a is inserted into a portion partially cut
out from the stationary cam 53 to be slidable in the radial
direction thereof, and is coupled with a piston rod 56a of a
piston-cylinder assembly 56 coupled with the frame, not shown, at a
portion inside the wheel 36c. Further, a recessed portion 55a, into
which the additional cam follower 31b is fitted, is formed to a
portion of the additional cam 55 corresponding to the movable cam
53a.
[0204] The discharge means is further provided with a cylindrical
shooter for discharging the defective bottle denoted by the
reference numeral 57 in FIGS. 2 and 5.
[0205] When a signal representing that the bottle 1, which is
judged as defective product by the inspection section 8, is
defective, is generated, the piston-cylinder assembly in the
expanded state as shown in FIG. 9A is contracted as shown in FIG.
9B, and the movable cam 53a is retired in the radially inside
direction of the cam 53. Accordingly, the additional cam follower
31b is invaded into the recessed portion 55a of the additional cam
55, and the paired clamp pieces 28a, 28b of the gripper 28 are
opened as shown with solid line from the closed state shown with
two-dot-chain-line, thus releasing the defective bottle 1. The
bottle 1 as defective product drops down from the gripper 28, and
then transferred to a predetermined collecting section through the
shooter 57. The bottle 1 judged to be a good product passes through
the discharge means, because the movable cam 53a is held at the
position shown in FIG. 9A, and then is transferred to the
sterilization section 9.
[0206] As shown in FIG. 2, the sterilization section 9 is connected
to the bottle inspection section 8. The bottle sterilization
section 9 is also entirely covered with the chamber 9a.
[0207] The wheel row coupled with the final end wheel 36c as bottle
travelling means on the inspection section side is provided inside
of the chamber 9a of the sterilization section 9. More
specifically, this wheel row is composed of two wheels 58a, 58b,
and a bottle travelling path is formed around outer peripheral
portions of these wheels 58a, 58b. Grippers 28, each having a
structure similar to that of the gripper 28 shown in FIG. 4, are
disposed around these wheels 58a and 58b, respectively.
[0208] The gripper 28 transfers the bottle 1 from the start end
wheel 58a to the final end wheel 58b while gripping the bottle neck
portion 1a and swivelling around these wheels. According to such
motion, the good bottle 1 after the inspection is continuously
travelled on the travelling path from the final end wheel 36c in
the inspection section 8 towards the final end wheel 58b in the
sterilization section 9. The gripper 28 grips the bottle neck
portion 1a by the clamp pieces 28a and 28b during the travelling of
the bottle 1, and the bottle 1 is hence travelled in the vertically
suspended state.
[0209] A spray tube 59 as condensed mist supply means for supplying
condensed mist .alpha. of the hydrogen peroxide as a sterilizing
agent for the bottle 1 is disposed to a predetermined portion
around the intermediate wheel 58b contacting from the downstream
side to the start end wheel 58a in the chamber 9a of the
sterilization section 9 as shown in FIG. 3L. The spray tube 59 is
fixed to a predetermined position so that a front end formed with a
nozzle hole of the spray tube 59 directly faces the opening of the
neck portion 1a of the good bottle 1 travelling just below the
nozzle hole.
[0210] Furthermore, as shown in FIG. 3L, a tunnel 60 may be formed
along the bottle travelling path below the spray tube 59 as
occasion demands.
[0211] One or a plurality of the spray tube 59 may be disposed,
which is arranged along the outer periphery of the intermediate
wheel 58b. In the shown embodiment, although the spray tube 59 is
disposed around the intermediate wheel 58b, the spray tube 59 may
be arranged around the other wheel.
[0212] The condensed mist .alpha. of the hydrogen peroxide is
produced by condensing the hydrogen peroxide sprayed and heated by
the mist producing device 61 shown in FIG. 10.
[0213] This mist producing device 61 is provided with a hydrogen
peroxide supply unit 62 as two-fluid spray for supplying solution
of the hydrogen peroxide, in form of drops, as sterilizing agent
and a vaporizer 63 for heating the sprayed mist of the hydrogen
peroxide supplied from the hydrogen peroxide supply unit 62 to a
temperature more than boiling point and less than undecomposed
temperature thereof and then gasifying it.
[0214] The hydrogen peroxide supply unit 62 sprays the solution of
the hydrogen peroxide into the vaporizer 63 by introducing the
solution through a hydrogen peroxide supply path 62a and a
compressed air through a compressed air supply path 62b.
[0215] The vaporizer 63 is composed of a pipe including a heater
63a interposed between inner and outer wall sections thereof, and
serves to heat and vaporize the spray mist of the hydrogen peroxide
sprayed into the pipe. The vaporized hydrogen peroxide gas is
jetted, as condensed mist .alpha. toward the opening of the neck
portion 1a of the bottle 1 through a spray nozzle 59.
[0216] The bottle 1 is conveyed around the wheel 58b with the neck
portion 1a being directed upward, and the lower end of the spray
tube 59 is opened toward the neck portion 1a of the bottle 1 at the
portion above the bottle travelling (conveying) path. The condensed
mist .alpha. of the hydrogen peroxide supplied into the spray tube
59 is continuously blown toward the bottle neck portion 1a through
the nozzle hole formed to the lower end of the spray tube 59. The
thus blown condensed mist .alpha. flows into the bottle 1 from the
neck portion 1a of the travelling bottle 1 and sterilizes the inner
surface of the bottle 1, and the other condensed mist .alpha. of
the hydrogen peroxide flows outside of the bottle 1 so as to
sterilize the outer surface of the bottle 1. At this instance,
since the bottle 1 travels in the tunnel 60, the condensed mist
.alpha. can be uniformly supplied to the outer surface of the
bottle 1.
[0217] As shown in FIG. 2, an air rinse section 96 for the bottle 1
is connected to the sterilization section 9 for the bottle 1. This
air rinse section 96 is entirely covered with a chamber 96a.
[0218] In the chamber 96a, wheel row coupled with the final end
wheel 58b as the travelling means for the bottle 1 on the
sterilization section side is provided, as shown in FIG. 2. More
specifically, this wheel row includes four wheels 58c, 58d, 58f and
92a, and a bottle travelling path is formed around the outer
peripheries of these wheels. Further, around these wheels 58d, 58d,
58e and 92a, grippers 28 similar to the gripper 28 shown in FIG. 7
are arranged.
[0219] The grippers 28 swivel around the respective wheels 58c,
58d, 58e and 92a with the neck portions 1a of the bottles 1 being
gripped and then transfer the bottles 1 from the start end wheel
58c to the final end wheel 92a subsequently. According to such
motion, the good bottles after the inspection continuously travel
on the travelling path from the final end wheel 58b in the
sterilization section 9 to the final end wheel 92a in the air rinse
section 96. Since each of the grippers 28 grips the neck portion 1a
of the bottle 1 during the travelling thereof by the clamp pieces
28a and 28b, the bottle 1 is travelled in the vertically suspended
state.
[0220] Air rinse means for cleaning the bottle 1 by supplying
aseptic heated air or normal temperature air to the bottle 1 is
further disposed around an intermediate wheel 58c in the next stage
contacting to the afore-mentioned intermediate wheel 58b from the
downstream side thereof.
[0221] This air rinse means is provided with a nozzle 64 for
jetting an aseptic air .gamma. or normal temperature air as shown
in FIG. 3M and FIG. 11.
[0222] As shown in FIG. 11, the wheel 58c rotated by the power from
a predetermined drive source is mounted horizontally to a
swivelling shaft 66 standing upward from the machine table 65. A
column 66a extends upward from the surface of the wheel 58c, and a
manifold 67 into which the heated air flows is fixed to the upper
end portion of the column 66. A conduit 68 extends upward on a line
extending from the axis of the swivelling shaft 66 at the upper
central portion of the manifold 67, and the conduit 68 is held
through a bearing 69 to a frame member of the chamber 9a connected
to the machine table 65. Accordingly, the manifold 67 is rotatable
around the swivelling shaft 66 integrally with the wheel 58c.
[0223] In addition, another column 70 extends upward from the
surface of the wheel 58c, and the gripper 28 of the bottle 1 is
attached to the upper portion of the column 70. A plurality of such
columns 70 and grippers 28 are arranged around the wheel 58c at
predetermined pitches, respectively. These grippers 28 are coupled
with the wheel 58c through the columns 70 so as to be rotatable in
accordance with the rotation of the wheel 58c.
[0224] These grippers 28 have substantially the same structures as
those shown in FIG. 4. Further, in a case when any inconvenience is
caused to the mist generating device 61 of the sterilization
section 9 or like and a bottle 1 defective in sterilization effect
is caused, a mechanism similar to the discharge means shown in
FIGS. 8 and 9 for removing the defective bottle from the travelling
path may be disposed. In FIG. 2, reference numeral 71 denotes a
shooter for dropping the bottle 1 defective in sterilization effect
to be removed from the bottle travelling path.
[0225] Heated air supply tubes 72 for supplying the heated air
.gamma. extend from a portion around the manifold 67 toward the
grippers 28, respectively, and the nozzles 64 are mounted to the
front end portions of the supply tubes 72. The nozzles 64 are fixed
to the columns 70 and the nozzle holes formed to the front ends of
the nozzles 64 are directed to the openings of the neck portions 1a
of the bottles 1 held by the grippers 28. According to this
arrangement, when the wheel 58c is rotated, the nozzle 64 is also
rotated around with the swivelling shaft 66 together with the
bottle 1 held by the gripper 28 so as to blow the heated air
.gamma. into the bottle 1.
[0226] Another stationary conduit 74 is connected to the upper end
portion of the conduit 68 of the manifold 67 through a seal member
75. The conduit 68 is rotated integrally with the manifold 67 with
respect to the conduit 74, and the seal member 75 prevents the
heated air .gamma. from leaking through the connection portion
between both the conduits 68 and 75.
[0227] Furthermore, a hot air supply device composed of a blower
76, an ultra low penetration air (ULPA) filter 77 and an electric
heater 78 is disposed on the upstream side of the conduit 75. The
air blown from the blower 76 is cleaned by the ULPA filter 77,
heated by the electric heater 78 to a predetermined temperature,
and fed into the conduit 74 as the heated air .gamma.. This heated
air .gamma. is an aseptic air, which was heated, for example, to a
temperature of more than 100.degree. C. The heated air .gamma. then
reaches the manifold 67 and blows outward into the bottles 1
through the nozzles 64 of the heated air supply tubes 72,
respectively, or blows outside the bottles 1.
[0228] A tube (pipe) line extending from the conduit 74 to the
nozzle 64 through the manifold 67 is formed to have a length as
short as possible, and accordingly, the heated air .gamma. can
reach the bottle 1 without being condensed.
[0229] When the heated air .gamma. is blown into the bottle 1 from
the nozzle 64, the heated air .gamma. uniformly contacts to the
entire inner surface of the bottle 1 and removes extra amount of
the hydrogen peroxide blown from the spray tube 59.
[0230] Further, it may be desired that the heated air .gamma. is
blown for a time during which the condensed mist .alpha. of the
hydrogen peroxide floating in the inner space of the bottle 1 can
be entirely exhausted. In a case where the temperature of the
heated air .gamma. is more than a resisting temperature for the
bottle 1, if the blowing time is so long, the bottle 1 is heated to
a temperature over the resisting temperature, which may result in
deformation of the bottle. Thus, in such case, a caution should be
paid.
[0231] Furthermore, as occasion demands, it may be possible to
gasify the hydrogen peroxide by mixing the condensed mist .alpha.
of low density hydrogen peroxide to aseptic air of normal
temperature in place of the heated air .gamma. and to supply the
gasified hydrogen peroxide so as not to be condensed.
[0232] As mentioned above, by supplying the sterilized heated air
.gamma. into the bottle 1 and performing the air rinse treatment,
the bottle 1 can be heated from the inner surface thereof, and the
sterilizing effect by the condensed mist .alpha. of the hydrogen
peroxide can be enhanced.
[0233] In the illustrated embodiment of the present invention,
although the nozzle 64 serves to blow the heated air .gamma. into
the bottle 1 from the outside of the bottle 1, the nozzle 64 may be
disposed to be vertically movable to be invaded into the bottle 1
when the heated air .gamma. is blown into the bottle 1.
[0234] The travelling speed of at least the gripper 28 arranged at
a portion between the start end wheel 36a of the inspection section
8 to the final end wheel 92a in the sterilization section 9 is
controlled to a speed so that the heat remaining in the bottle at
the bottle forming period in the molding section 7 is maintained to
an extent necessary for the sterilization of the bottle 1 in the
sterilization section 9.
[0235] That is, as shown in FIG. 2, a servo-motor S1 is disposed to
the inspection section 8 to be driven so as to dynamically
interlock the whole wheels 36a, 36b and 36c in the inspection
section 8, and a servo-motor S2 is also disposed to the
sterilization section 9 and the air rinse section 96 to be driven
so as to dynamically interlock the whole wheels 58a, 58b, 58c, 58d,
58e and 92a in the sterilization section 8 and the air rinse
section 9. By controlling these servo-motors S1 and S2, the
travelling speed of the gripper 28 is regulated, and as a result,
the bottle 1 gripped by the gripper is conveyed to a portion
directly below the spray tube 59 in a state that the remaining heat
in the bottle 1 at the bottle molding time is maintained to an
extent necessary for the sterilization in the sterilization section
9. Further, the bottle 1 into which the condensed mist .alpha. of
the hydrogen peroxide is blown from the spray tube 59 in the
sterilization section 9 promptly reaches the air rinse section
96.
[0236] Further, it may be desired that the temperature of the
bottle 1 directly below the spray tube 59 is maintained to be more
than 50.degree. C. for properly attaining the sterilization effect
by the condensed mist .alpha. of the hydrogen peroxide. Especially,
the bottle neck portion 1a, the thickened portion such as bottle
bottom portion, and a portion, such as bottle bottom portion, to
which it is hard for the condensed mist to reach, are portions hard
to be sterilized. However, for the bottle 1 just after being
molded, these portions are in the highly heated state, so that
preferably high sterilization effect can be attained by the small
amount of condensed mist .alpha..
[0237] That is, according to the experiment performed by the
inventors of the present application, it was found that the density
of the hydrogen peroxide condensed on the surface of the bottle 1
becomes higher as the temperature of the bottle 1 becomes high.
This is considered that the hydrogen peroxide has a boiling point
higher than that of water. More concretely, in the cases of the
bottle temperatures of 50.degree. C., 65.degree. C. and 80.degree.
C., the densities (weight %) of the hydrogen peroxide adhering to
the surface of the bottle 1 were about 70%, 80% and 90%. Since the
density of the hydrogen peroxide adhering to the sterilizing agent
(hydrogen peroxide) on the surface of the bottle increases in
addition to the increased temperature, the bottle can be sterilized
by the small amount of hydrogen peroxide.
[0238] In the beverage filling apparatus of the present embodiment,
there is provided positive pressure creating means for creating
positive pressure in the inspection section 8 more than pressures
in the molding section 7 and the sterilization section 9.
[0239] That is, as shown in FIG. 12, an atmosphere shutoff chamber
79 is disposed between the chamber 8a of the inspection section 8
and the chamber 9a of the sterilization section 9. In addition, a
partition wall 35 is also disposed between the chamber 7a of the
molding section 7 and the chamber 8a of the inspection section 8,
and the partition wall 35 is formed with a bottle passing hole 35a
through which the bottle 1 can pass. Partition walls 80 and 81 of
the structure similar to that of the partition wall 35 are
disposed, respectively between the chamber 8a of the inspection
section 8 and the atmosphere shutoff chamber 79 and between the
atmosphere shutoff chamber 79 and the chamber 9a of the
sterilization section 8. Furthermore, a partition wall 82 of the
structure similar to that of the above mentioned partition wall is
disposed so as to separate the portion at which the condensed mist
.alpha. of the hydrogen peroxide is sprayed from the spray tube 59
from the portion at which a hydrogen peroxide gas .beta. is
jetted.
[0240] An air supply duct 83 is connected to the chamber 8a of the
inspection section 8 as air supply means for supplying the cleaned
air, and an air supply blower 84, a filter 85 and a heater 97 are
provided for this air supply duct 83. The air is heated by the
heater 97, and the heated air contacts the bottle 1 travelling in
the chamber 8a, so that the bottle 1 is protected from being
cooled, or is further heated. Incidentally, the heating by the
heater 97 may be eliminated if the remaining heat at the bottle
molding time does not substantially effect the sterilization in the
sterilization section 9.
[0241] By blowing the cleaned air into the chamber 8a of the
inspection section 8 by the air supply means, a positive pressure
state such as of 3 Pa higher than atmospheric pressure is created
in the chamber 8a of the inspection section 8.
[0242] An air exhaust duct 86, as air exhaust means, is coupled
with the atmosphere shutoff chamber 79, and an air exhaust blower
87 and a filter 88 are provided for this air exhaust duct 86.
Another air exhaust duct 89 may be coupled with a portion adjacent
to the atmosphere shutoff chamber 79 in the chamber 9a of the
sterilization section 9, as occasion demands, and this air exhaust
duct 89 is connected to the exhaust duct 86 coupled with the
atmosphere shutoff chamber 79. According to the location of the air
exhaust means, the interior of the atmosphere shutoff chamber 79 is
maintained at a pressure of 0 Pa (zero Pa) substantially equal to
the atmospheric pressure.
[0243] Furthermore, an air supply duct as supply means, not shown,
for supplying the cleaned air is coupled with a chamber 10a of a
filling section which will be mentioned herein later, and the air
supply blower and the filter are provided for this air supply duct.
By the location of such air supply means, the cleaned air is blown
into the chamber 10a of the filling section 10 at a pressure of
approximately 20 to 100 Pa. This cleaned air flows into the chamber
9a of the sterilization section 9 through the chamber 96a of the
air rinse section 96, and creates the positive pressure (about 10
Pa) state in the chamber 9a of the sterilization section 9.
Thereafter, the cleaned air flows outward of the chamber 9a of the
sterilization section 9 and the atmosphere shutoff chamber 79
through the duct 89 of the chamber 9a and the duct 86 of the
chamber 79, respectively.
[0244] Further, the interior of the chamber 7a of the molding
section 7 is maintained at 0 Pa approximately equal to the
atmospheric pressure.
[0245] The partition wall 81 disposed between the atmosphere
shutoff chamber 79 and the chamber 9a of the sterilization section
9 is formed with a bottle passing hole 81a and an air nozzle 90 for
shutting off the passing hole 81a with air curtain may be disposed
as occasion demands.
[0246] By the location of such positive pressure creating means,
the condensed mist .alpha. and the gas .beta. of the hydrogen
peroxide flowing into the chamber 9a of the sterilization section 9
are exhausted externally of the chamber 9a through the duct 89, and
on the other hand, the cleaned air introduced into the chamber 8a
of the inspection section 8 flows toward the chamber 7a of the
molding section 7 and the atmosphere shutoff chamber 79, thus
preventing contaminated air and air containing the hydrogen
peroxide from entering the chamber 8a of the inspection section 8.
Furthermore, even if the air is sucked into the chamber 8a of the
inspection section 8 from the chamber 7a of the molding section 7
in accordance with the travelling of the bottle 1, such air is
prevented from entering the chamber 9a of the sterilization section
9 by the exhaust gas from the atmosphere shutoff chamber 79, thus
appropriately preventing the contamination in the sterilization
section.
[0247] As shown in FIG. 2, the filling section 10 is coupled with
the air rinse section 96 and entirely covered with a chamber 10a. A
partition wall, not shown, is disposed between the chamber 96a of
the air rinse section 96 and the filling section 10, and this
partition wall is formed with a bottle passing hole through which
the bottle 1 passes.
[0248] The chamber 10a of the beverage filling section 10 is
connected, as shown in FIG. 2, to a wheel row coupled with the
final end wheel 92a as the bottle travelling path on the air rinse
section side.
[0249] More specifically, this wheel row includes four wheels 94c,
94d, 94e and 94f, and a bottle travelling path is formed to the
outer peripheries of these four wheels. Grippers 28 similar to
those shown in FIG. 4 are arranged around the wheels 94c, 94d, 94e
and 94f, respectively.
[0250] Inside the chamber 10a of the beverage filling section 10,
the bottles 1 are transferred from the start end wheel 94c to the
final end wheel 94f while grippers 28 turning around these wheels
with the bottle neck portions 1a being held. According to such
motion, the bottles 1 can be continuously travelled in the beverage
filling section 10 from the start end wheel 94c to the final end
wheel 94f. Each of the grippers 28 grips the neck portion 1a of the
bottle 1 by its clamp pieces 28a and 28b in the vertically
suspended attitude of the bottle 1 during the bottle
travelling.
[0251] A beverage filling machine is placed to a predetermined
position around the start end wheel 94c, having a larger diameter,
in the chamber 10a of the beverage filling section 10. As shown in
FIG. 3N, the beverage "a", which was preliminarily subjected to the
sterilization process, fills the bottle 1 through the nozzle 95 of
the beverage filling machine. This nozzle 95 is travelled in
synchronous with the travelling of the bottle 1, and a constant
amount of the beverage "a" fills the bottle 1 during the parallel
travelling with the bottle 1.
[0252] A capper is arranged to a predetermined position around the
intermediate wheel 94e downstream side of the beverage filling
machine. As shown in FIG. 3O, the cap 2 is mounted to the neck
portion 1a of the bottle 1 by means of this capper, thus sealing
the bottle 1.
[0253] The bottle 1 filled up with the beverage "a" and then sealed
by the cap 2 is released from the gripper 28 of the final end wheel
94f and discharged outside of the beverage filling machine through
an outlet formed to the chamber 10a.
[0254] Further, since these beverage filling machine and the capper
are known ones, the detailed explanation thereof is omitted
herein.
[0255] Furthermore, as shown in FIG. 2, the beverage filling
section 10 is provided with two servo-motors S5 and S6 driven so as
to be dynamically interlocked in a predetermined combination of the
wheels 94c, 94d, 94e and 94f inside the beverage filling section
10. The first serve-motor S5 of these two servo-motors serves to
drive the start end wheel 94c around which the beverage filling
machine is disposed, and the second servo-motor S6 serves to drive
the wheels 94d, 94e and 94f disposed downstream side of the
intermediate wheel 94c.
[0256] According to the arrangement described above, even if the
wheels and the grippers in the respective sections of the
inspection section 8, the sterilization section 9, the air rinse
section 96 and the beverage filling section 10 have the structures
different from each other, the synchronous driving of the grippers
can be achieved by controlling the servo-motors S1, S2, S5 and S6,
and hence, the bottles 1 can be smoothly continuously travelled
into the beverage filling section 10 from the molding section
7.
[0257] Further, in the described embodiment, although the molding
section 7 is driven by a known electric motor, not shown, the
wheels and the turntable in the molding section 7 may be driven by
a servo-motor.
[0258] Hereunder, the operation of the beverage filling apparatus
of the structures mentioned above will be described.
[0259] (1) First, a preform 6 shown in FIG. 3A is prepared. The
preform 6 is subjected to the injection molding, and thereafter, is
fed to a preform supply machine 11 of the beverage filling
apparatus of the present invention. The preform 6 is fed into the
molding section 7 by means of conveyer 12 of the preform supply
machine 11.
[0260] (2) The preform conveyed in a vertically standing state by
the conveyer 12 as shown in FIG. 3A is transferred to the gripper
of the start end wheel 13a continuously rotating in the molding
section 7, and is then inverted in attitude by the gripper of the
intermediate wheel 13b.
[0261] The inverted preform 6 is covered to the mandrel 17 of the
first turn table 14a from the neck portion 1a, as shown in FIG.
3B.
[0262] The mandrel 17 covered with the preform 6 is, as shown in
FIG. 3C, travelled, while revolving, inside the heating chamber 16,
and the preform 6 is also continuously travelled, while revolving
with the mandrel 17, in the heating chamber 16. Accordingly, the
preform 6 can be uniformly heated to a temperature capable of being
subjected to the blow-forming.
[0263] (3) The heated preform 6 is clamped, as shown in FIG. 3D, by
the blow-forming molds 18, and air is blown into the preform 6
through the blow nozzle 19 penetrating the mandrel 17 to thereby
form the bottle 1 in the mold 18.
[0264] The molded bottle 1 is taken out of the mold 18 together
with the mandrel 17 by opening the mold halves, and as shown in
FIG. 3E, the bottle 1 is conveyed to the first turntable 14a in the
inverted state through the sixth turntable 14f.
[0265] (4) The bottle 1 held by the mandrel 17 at the first
turntable 14a is gripped as shown in FIG. 3F, by a gripping member
98 of the start end wheel 19a and inverted so as to take the normal
vertical attitude. In this operation, the gripping member 98 grips
a portion of the bottle 1 above the support ring 5 of the neck
portion 1a. Subsequently, the bottle 1 is received by the gripper
28 of the final end wheel 19b as shown in FIG. 4. The gripper 28
grips, at this time, the portion lower than the support ring 5 of
the bottle neck portion 1a as shown in FIG. 6.
[0266] (5) Then, the gripper 37 of the start end wheel 36a of the
inspection section 8 grips a portion upper than the support ring 5
of the bottle neck portion 1a and receives the bottle 1 from the
final end wheel 19b of the molding section 7, and the bottle 1
swivels while being held by the gripper 37.
[0267] During this swivelling operation, as shown in FIG. 3G, the
shell portion of the bottle 1 is inspected by the bottle shell
portion inspection means. In this inspection, the image of the
shell portion of the bottle picked up by the camera 45 is processed
by the image processing device, not shown, and it is discriminated
whether any abnormality such as injury, foreign material,
discoloration or like exists.
[0268] (6) The bottle 1 is then transferred from the gripper 37 of
the start end wheel 36a to the gripper 28 of the intermediate wheel
36b, and the gripper 28 of the intermediate wheel 36b grips the
lower side of the support ring 5 of the bottle neck portion 1a and
swivels as shown in FIG. 3H and FIG. 6.
[0269] During this swivelling motion, as shown in FIG. 3H, the
temperature of the bottle 1 is detected by the temperature sensor
46 of the temperature detecting means. In this temperature
detection, if the detected temperature does not reach 50.degree.
C., it is discriminated that this bottle 1 is a defective
product.
[0270] (7) Subsequently, as shown in FIG. 3I, the surface condition
of the support ring 5 of the bottle 1 is inspected by the support
ring inspection means. In this inspection, the image of the upper
face of the support ring 5 picked up by the camera 48 is processed
by the image processing device, not shown, and it is discriminated
whether any abnormality such as injury, foreign material,
discoloration or like exists.
[0271] (8) Subsequent to the support ring inspection, as shown in
FIG. 3J, the surface condition of the upper face 1d of the bottle
neck portion 1a is inspected by the bottle neck portion upper face
inspection means. In this inspection, the image of the upper face
1d of the bottle neck portion 1a picked up by the camera 50 is
processed by the image processing device, not shown, and it is
discriminated whether any abnormality such as injury, foreign
material, discoloration or like exists.
[0272] (9) Subsequent to the bottle neck portion upper face
inspection, as shown in FIG. 3K, the bottom condition of the bottle
1 is inspected by the bottle bottom portion inspection means. In
this inspection, the image of the bottom portion of the bottle 1
picked up by the camera 52 is processed by the image processing
device, not shown, and it is discriminated whether any abnormality
such as injury, foreign material, discoloration or like exists.
[0273] (10) The bottle 1 subjected to the above respective
inspections is held by the gripper 28, shown in FIG. 8, of the
final end wheel 36c of the inspection section 8. In an event that
an abnormal signal informing an occurrence of an abnormality is
generated from any one of the respective inspection means, as shown
in FIG. 9, the gripper releasing mechanism is operated, and a pair
of clamping pieces 28a and 28b of the gripper 28 is moved from the
closed position shown with two-dotted-chain line to the opened
position shown with solid line to thereby release the defective
bottle 1.
[0274] According to such operation, the defective bottles 1, to
which any abnormal condition is caused to the shell portion, the
bottom portion, the neck upper face 1d and the support ring 5 of
the bottle 1, are discharged (rejected) from the bottle travelling
path, and the bottles 1, which are not subjected to sufficient
sterilization effect by the hydrogen peroxide even if heated in the
subsequent sterilization process, are also discharged (rejected)
from the travelling path.
[0275] On the other hand, the good bottles 1 pass through the
bottle discharging means, because the movable cam 53a is held to
the position shown in FIG. 9A, and move toward the sterilization
section 9.
[0276] (11) The good bottle 1 is transferred from the gripper 28 of
the final end wheel 36c of the inspection section 8 to the gripper
28 of the start end wheel 58a of the sterilization section 9, and
then, transferred to the gripper of the wheel disposed downstream
side, thus being continuously travelled.
[0277] When the good bottle 1 is travelled around the intermediate
wheel 58b while being held by the gripper 28, the good bottle 1
travels directly below the spray tube 59 as shown in FIG. 3L.
Accordingly, the condensed mist .alpha. of the hydrogen peroxide
jetted from the spray tube 59 is brown against the bottle 1 to
thereby sterilize the inner and outer surfaces of the bottle 1. As
mentioned above, since the good bottles 1 having proper remaining
heat are only travelled, these bottles 1 can be properly sterilized
by the condensed mist .alpha. of the hydrogen peroxide, and
thereafter, are travelled toward the downstream side.
[0278] (12) The bottle 1 blown with the condensed mist .alpha. of
the hydrogen peroxide in the sterilization section 9 is travelled
around the intermediate wheel 58c while being held by the gripper
28. During this travelling, the heated air .gamma. is brown through
the nozzle 64 as shown in FIG. 3M. Accordingly, the inner and outer
surfaces of the bottle 1 can be cleaned through the air rinse
process to thereby remove the excessive hydrogen peroxide adhering
to the inner and outer surfaces of the bottle 1.
[0279] Further, it is desired that the bottle 1 blown with the
condensed mist .alpha. of the hydrogen peroxide from the spray tube
59 at the sterilization section 9 reaches inside the air rinse
section 96 within 0.1 to 5.0 second, and in a case of less than 0.5
second, sufficient sterilization effect will not be expected
because of too short sterilizing time, and on the contrary, in a
case of more than 5.0 seconds, the hydrogen peroxide will intrude
inside the inner layer of the PET wall, and the remaining amount of
the hydrogen peroxide will increase, which will require location of
such aseptic water rinse section 91 as mentioned hereinafter with
respect to a second embodiment.
[0280] Test result exhibiting ground of the above matter will be
shown hereunder.
[0281] The inventors of the present application measured the
sterilization effects and remaining hydrogen peroxide density with
respect to B. subtilis spore by using a PET bottle of 500 mL
volume. The measured results are shown in the following table
(Table 1).
TABLE-US-00001 TABLE 1 From hydrogen peroxide spray Log Reduction
(LR) NO. to air-rinse 0.5 sec 2 sec 5 sec 1 Remaining 0.3 ppm 0.4
ppm 0.9 ppm hydrogen peroxide Judgement .largecircle. .largecircle.
X 2 Log reduction 4.5Log 6Log >6Log Judgement X .largecircle.
.largecircle. Total judgment X .largecircle. X
[0282] Evaluation method to the measurement was as follows.
Sterilization Effects (Log Reduction)=Log (Number of Adhering
Bacteria/Number of Survived Bacteria)
[0283] Index Bacteria: B. subtilis var. niger ATCC9372
[0284] Remaining Hydrogen Peroxide Density Measurement: Measured by
Oxygen Electrode Method
[0285] Sterilizing Process: A bottle was taken out from a blow
injection mold, condensed mist of hydrogen peroxide was sprayed to
the bottle, and air rinse treatment was performed.
[0286] The hydrogen peroxide was supplied by 30 .mu.L. The
condensed mist of the hydrogen peroxide was sprayed within 30
seconds after the separation of the bottle from the mold. This is
because the high sterilization effect by the hydrogen peroxide is
obtained as high as the temperature of the bottle after the
separation from the mold, and if the heat escapes from the bottle
and the bottle is cooled, the hydrogen peroxide is condensed on the
PET wall surface of the bottle and is likely adsorbed into the PET
inner layer.
[0287] As is apparent from the Table 1, after 2 seconds from the
spraying of the hydrogen peroxide, when the air rinsing process is
initiated, the remaining hydrogen peroxide becomes less than 0.5
ppm and the sterilization effect becomes more than 6 Log.
[0288] (13) As shown in FIG. 12, the positive pressure creating
means is arranged on the way of the travelling path of the bottle 1
which is travelled from the molding section 7 to the sterilization
section 9, and accordingly, the excessive amount of the mist
.alpha. of the hydrogen peroxide flowing into the chamber 9a of the
sterilization section 9 is discharged outside of the chamber 9a
through the ducts 86 and 89, and on the other hand, the cleaned air
flowing into the chamber 8a of the inspection section 8 flows
toward the chamber 7a of the molding section 7 and the atmosphere
shutoff chamber 79 to thereby prevent the contaminated air or air
containing hydrogen peroxide from flowing into the chamber 8a of
the inspection section 8.
[0289] Furthermore, even if the air is pulled into the chamber 8a
of the inspection section 8 from the chamber 7a of the molding
section 7 in accordance with the travelling of the bottle 1, this
air is prevented from entering into the chamber 9a of the
sterilization section 9 by the exhaust from the atmosphere shutoff
chamber 79, thus effectively preventing the contamination of the
interior of the sterilization section 9.
[0290] (14) During the conveyance of the bottle 1 toward the
downstream side of the sterilization section 9 through the
inspection section 8, in occurrence of an event that any
abnormality is caused on the molding section 7 and the wheel row on
the molding section side emergently stops in operation, as shown in
FIG. 7, the piston rod 42a of the piston-cylinder assembly 42 is
contracted to thereby open the paired clamp pieces 37a, 37b in the
closed state by about 180 degrees.
[0291] Accordingly, the interference between the gripper 28 mounted
to the final end wheel 19b of the molding section 7 and the gripper
37 mounted to the start end wheel 36a of the inspection section 8
can be effectively prevented.
[0292] Furthermore, since the start end wheel 36a and the following
wheel row are being continuously rotated, the bottle 1 introduced
into the inspection section 8 is continuously travelled downstream
side. Accordingly, the normally formed bottle 1 is subjected to the
inspection in the inspection section 8 and the bottle 1 passing
through the inspection section 8 is travelled toward the
sterilization section 9, thus the bottle being processed
laconically. Moreover, even if the molding section 7 stops in
operation, since the respective sections following the inspection
section 8 can be operated, the bottle 1 can be continuously
travelled through the sections following the sterilization section
9, thus preventing the excessive adhering of the hydrogen peroxide
due to the stopping of the bottle in the sterilization section 9
and also preventing the insufficient sterilization due to the
cooling of the bottle 1, and accordingly, the only the normal
bottles 1 can be filled with beverage.
[0293] (15) The bottle 1 subjected to the air-rinsing treatment is
conveyed to the beverage filling section 10, and when the bottle is
travelled around the wheel 94c while being gripped by the gripper
28, as shown in FIG. 3N, a predetermined amount of the beverage "a"
from the beverage filling machine is supplied into the bottle
1.
[0294] (16) The bottle 1 filled with the beverage "a" is travelled
around the wheel 94e while being gripped by the gripper 28, and at
this period, as shown in FIG. 3O, the cap 2 is applied to the
bottle neck portion 1a by the capper. According to this operation,
the bottle 1 is sealed as a beverage packaging bottle.
[0295] The bottle 1 as the beverage packaging bottle is then fed
out externally from the beverage filling apparatus.
Second Embodiment
[0296] A second embodiment of the beverage filling apparatus for
filling the bottle 1 with the beverage will be described
hereunder.
[0297] As shown in FIG. 13, the beverage filling apparatus of this
second embodiment is provided with the bottle molding section 7,
the inspection section 8 for inspecting the molded bottle 1, the
bottle sterilization section 9, the bottle air rinse section 96,
the bottle aseptic water rinse section 91, and a beverage filling
section 10 for filling the bottle 1 with the beverage "a" and then
sealing the bottle 1.
[0298] The structure or arrangement ranging from the molding
section 7 to the sterilization section 9 are substantially the same
as that in the first embodiment, so that the duplicated explanation
is omitted herein.
[0299] As shown in FIG. 13, the air rinse section 96 for the bottle
1 is coupled with the sterilization section 9, and the air rinse
section 96 is entirely covered with the chamber 96a.
[0300] A wheel row coupled with the final end wheel 58b, as bottle
travelling means, on the side of the sterilization section 9 for
the bottle 1 is connected to the inside of the chamber 96a of the
air rinse section 96, as shown in FIG. 13. More specifically, this
wheel row includes three wheels 58c, 58d and 58e, around which a
bottle travelling path is formed. Further, grippers 28 similar to
the grippers 28 shown in FIG. 4 are also arranged around these
wheels 58c, 58d and 58e.
[0301] The grippers 28 grip the neck portions 1a of the respective
bottles 1, and in this state, the bottles 1 are turned around the
respective wheels 58c, 58d and 58e and then transferred from the
start end wheel 58c to the final end wheel 58e. Accordingly, the
good bottles 1 after the inspection are travelled continuously
along the travelling path from the final end wheel 36b in the
sterilization section 9 to the final end wheel 58e in the air rinse
section 96. Since the gripper 28 grips the neck portion 1a of the
bottle 1, the bottle 1 is travelled in the vertically suspended
attitude.
[0302] Air rinse means for cleaning the bottle 1 by supplying the
heated air .gamma. mixed with the hydrogen peroxide gas .beta. as
the sterilizing agent is disposed around the start end wheel
58c.
[0303] This air rinse means is provided with a nozzle 64
discharging the heated air .gamma. mixed with the hydrogen peroxide
gas .beta. as shown in FIG. 14A and FIG. 17.
[0304] As shown in FIG. 17, the wheel 58c rotating by the power
from a predetermined power source is horizontally mounted to the
swivelling shaft 66 standing from the machine table 65. Columns 66a
extend upward from the surface of the wheel 58c and a manifold 67
into which the heated air mixed with the hydrogen peroxide gas
.beta. is fed is fixed to the upper end portions of the columns
66a. A conduit 68 extends upward on an extension of an axis of the
swivelling shaft 66 from the upper central portion of the manifold
67, and the conduit 68 is held by a frame member of the chamber 9a
coupled with the machine table 65 through a bearing 69.
Accordingly, the manifold 67 becomes rotatable around the
swivelling shaft 66 integrally with the wheel 58c.
[0305] Furthermore, other columns 70 extend upward from the surface
of the wheel 58c, and grippers 28 are mounted to the upper end
portions of the respective columns 70, and a plurality of columns
70 and grippers 28 are disposed around the wheel 58c at
predetermined pitches. Since the grippers 28 are coupled with the
wheel 58c through the columns 70, the grippers 28 are rotated
together with the rotation of the wheel 58c.
[0306] These grippers 28 have substantially the same structures as
those shown in FIG. 4.
[0307] Furthermore, in an event that any inconvenient matter is
caused, for example, to the mist generation device 61 of the
sterilization section 9 and an insufficiently sterilized bottle 1
is produced, such bottle 1 is discharged or rejected from the
travelling path by a mechanism as discharging means of the
structure similar to that shown in FIGS. 8 and 9. Further, in FIG.
2, reference numeral 71 denotes a shooter for falling down the
insufficiently sterilized bottle 1 to be discharged by the
discharging means from the travelling path.
[0308] A plurality of supply tubes 72 for supplying the heated air
.gamma. mixed with the hydrogen peroxide gas .beta. toward the
respective grippers 28 extend around the manifold 67, and the
nozzles 64 are formed to the distal end portions of the respective
supply tubes 72. Each of the nozzles 64 is fixed to the column 70
and a nozzle opening formed to the distal end of the nozzle 64 is
directed to the opening of the neck portion 1a of the bottle 1 held
by the gripper 28. According to such arrangement, when the wheel
58c is rotated, the nozzle 64 is turned around the swivelling shaft
66 together with the bottle 1 held by the gripper 28 and the heated
air .gamma. mixed with the hydrogen peroxide gas .beta. is blown
into the bottle 1.
[0309] A duct 74a is connected to the upper end of the conduit 68
of the manifold 67 through a seal member 75. The conduit 68 rotates
together with the manifold 67 with respect to the duct 74a, and the
seal member 75 prevents the hydrogen peroxide gas .beta. from
leaking through the connecting portion between the conduit 68 and
the duct 74a. A plurality of mist generating devices 61 shown in
FIG. 10 is mounted to the duct 74a, and the condensed mist .alpha.
of the hydrogen peroxide is supplied into the duct 74a from the
respective mist generating devices 61. The number of the mist
generating devices 61 to be operated will be determined in
accordance with the amount of the hydrogen peroxide gas .beta.
required for the sterilization of the bottle 1.
[0310] A hot air supply device composed of a blower 76 and ultra
low air filter (ULPA Filter) 77 and a heater 78 is disposed on the
upstream side of the duct 74a. The air introduced through the
blower 76 is cleaned by the ULPA filter 77 and then heated by the
heater 78 to a predetermined temperature so as to create the hot
air .gamma., which is then fed into a heating tube 74a. The heated
air .gamma. is an aseptic air heated to a temperature more than a
dew point of the hydrogen peroxide, for example, 100.degree. C. The
heated air .gamma. acts to gasify the condensed mist .alpha. of the
hydrogen peroxide fed to the mist generation device 61 and conveys
the gasified mist to the manifold 67. The heated air .gamma. mixed
with the hydrogen peroxide gas .beta. is blown into the bottle 1
from the nozzle 64 through each of the supply tubes 72 or is blown
out of the bottle 1.
[0311] A line from the duct 74a to the nozzle 64 through the
manifold 67 is formed as possible as short, and because of this
reason, the hydrogen peroxide gas .beta. is not condensed and
reaches the bottle 1 together with the heated air .gamma..
[0312] When the heated air .gamma. mixed with the hydrogen peroxide
gas .beta. is blown into the bottle 1 from the nozzle 64, the
hydrogen peroxide gas .beta. contacts uniformly the entire inner
surface of the bottle 1 to thereby promptly and smoothly sterilize
the bottle inner surface.
[0313] Further, it is desirable that the density of the hydrogen
peroxide gas .beta. to be mixed into the heated air .gamma. is 1
mg/L to 10 mg/L (L: the hydrogen peroxide gas volume in the mixed
gas), and more preferably, 2 mg/L to 8 mg/L.
[0314] As mentioned above, by supplying the sterilized hydrogen
peroxide gas .beta. and the heated air .gamma. in the bottle 1 to
thereby perform the air rinse treatment, the bottle 1 is heated
from the inner surface thereof, which enhances the sterilizing
effect by the condensed mist .alpha. and the hydrogen peroxide gas
.beta.. In addition, for example, a bottom portion of the bottle 1,
which was insufficiently sterilized by the hydrogen peroxide
condensed mist .alpha. can be more sufficiently sterilized by the
hydrogen peroxide gas .beta. contained in the heated air
.gamma..
[0315] Further, the time for blowing the heated air .gamma.
containing the hydrogen peroxide gas .beta. will be determined
within a range by which all the condensed mist .alpha. of the
hydrogen peroxide floating inside the bottle 1 can be discharged
and the insufficient sterilization by the condensed mist .alpha. of
the hydrogen peroxide can be compensated for. In the case where the
temperature of the heated air .gamma. containing the hydrogen
peroxide gas .beta. is more than the resisting temperature of the
bottle 1, there may cause a case in which the bottle 1 is heated to
a temperature more than its resisting temperature and is deformed
unfairly if the heated air blowing time is too long, and hence,
attention should be paid. The blowing time of this heated air
.gamma. containing the hydrogen peroxide gas .beta. may be set to 2
to 5 seconds, for example.
[0316] Furthermore, as occasion demands, in place of the heated air
.gamma., the hydrogen peroxide is gasified by mixing the condensed
mist of the low density hydrogen peroxide with sterilized air of
normal temperature and such gasified hydrogen peroxide gas may be
supplied to the nozzle 64 so as not to be condensed.
[0317] As mentioned above, by performing the air rinse treatment by
supplying the sterilized heated air .gamma. containing the hydrogen
peroxide gas .beta. into the bottle 1, the bottle 1 is heated from
the inner surface thereof and the sterilizing effect by the
hydrogen peroxide gas .beta. contained in the heated air .gamma.,
for example, a bottom portion of the bottle 1, which was
insufficiently sterilized by the hydrogen peroxide condensed mist
.alpha. supplied from the spray tube 59 can be more sufficiently
sterilized by the hydrogen peroxide gas .beta. contained in the
heated air .gamma..
[0318] In the illustrated embodiment, although the hydrogen
peroxide gas .beta. contained in the heated air .gamma. is blown
into the bottle 1 with the nozzle 64 being disposed outside the
bottle 1, each nozzle 64 may be arranged to be vertically movable
so that the nozzle 64 enters the bottle 1 when the hydrogen
peroxide gas .beta. contained in the heated air .gamma. is blown
into the bottle 1. Furthermore, the nozzle 64 may be inserted into
the bottle 1 in the inverted attitude to thereby perform the air
rinsing treatment to thereby remove foreign materials or like.
[0319] The grippers 28 disposed between the start end wheel 36a in
the inspection section 8 and the final end wheel 58b in the
sterilization section 9 are controlled in their travelling speeds
such that the remaining heat of the bottles 1 at the bottle molding
process in the molding section 7 is maintained to an extent
necessary for the sterilization of the bottles 1 in the
sterilization section 9.
[0320] That is, as shown in FIG. 13, the servo-motor S1 for driving
all the wheels 36a, 36b, 36c in the inspection section 8 so as to
be dynamically interlocked with each other is disposed in the
inspection section 8, and the servo-motor S2 for driving all the
wheels 58a, 58b, 58c, 58d, 58e in the sterilization section 9 and
the air rinse section 96 so as to be dynamically interlocked with
each other is disposed in the sterilization section 9 and the air
rinse section 96.
[0321] According to the controlling of the servo-motors S1 and S2,
the travelling speed of the grippers 28 are adjusted, and as a
result, the bottle 1 gripped by the gripper 28, with the remaining
heat at the bottle molding time being maintained to the extent
necessary for the sterilization in the sterilization section 9, is
conveyed directly below the spray tube 59.
[0322] Further, the bottle 1 blown with the condensed mist .alpha.
of the hydrogen peroxide from the spray tube 59 at the
sterilization section 9 promptly reaches the air rinse section
96.
[0323] It may be desired that the temperature of the bottle 1
directly below the spray tube 59 is maintained more than 50.degree.
C. By maintaining the temperature more than 50.degree. C., the
sterilization effect by the condensed mist .alpha. of the hydrogen
peroxide can be properly achieved. Further, although it is hard to
sterilize the bottle neck portion 1a, the thickened portion such as
bottle bottom portion and the portions such as bottle bottom
portion to which the condensed mist hardly reaches, according to
the present embodiment, since in the bottle 1 immediately after the
molding process, these portions are highly heated, these portions
can be effectively sterilized even by a small amount of the
condensed mist .alpha..
[0324] In the beverage filling apparatus of this embodiment, there
is provided positive pressure creating means for making the
pressure in the inspection section 8 higher than the pressure in
the molding section 7 and the sterilization section 9 as like as in
the first embodiment mentioned hereinbefore. Since this positive
pressure creating means has substantially the same structure as
that of the first embodiment, the details thereof are omitted
herein
[0325] As shown in FIG. 13, an aseptic water rinse section 91 is
coupled with the air rinse section 96. This aseptic water rinse
section 91 is also entirely covered by a chamber 91a. A partition
wall, not shown, is disposed between the chamber 91 and the chamber
9a of the sterilization section 9 and a bottle passing hole is
formed to this partition wall.
[0326] A wheel row coupled with the final end wheel 58e of the
bottle travelling means on the sterilization section side is
connected to the chamber 91a of the aseptic water rinse section 91.
More specifically, this wheel row includes three wheels 92a, 92b,
92c, around which a bottle travelling path is formed.
[0327] Furthermore, grippers 28 similar to those shown in FIG. 4
are arranged around the start end wheel 92a and the final end wheel
92c, and a plurality of grippers 20, such as shown in FIGS. 15A and
15B, are also arranged around the intermediate wheel 92b having a
larger diameter, at constant pitches.
[0328] The gripper 20 has a pair of clamp pieces 20a and 20b for
clamping the neck portion 1a of the bottle 1 from the outside side
thereof. The paired clamp pieces 20a, 20b are supported to the base
portion 21 by means of vertical pins 22, 22 to be rotatable and
always pulled in the closing direction by means of tension spring
23. According to such structure, as shown in FIG. 15B, the paired
clamp pieces 20a, 20b always function to grip the neck portion 1a
of the bottle 1. A column-shaped vertical shaft pin 24 is attached
to the base portion 21 in a manner such that the vertical shaft pin
24 is slidable in the radial direction of the start end wheel 19a
with the shaft pin 24 being fitted into recessed portions formed to
root portions of the clamp pieces 20a and 20b. A cam follower 25 is
coupled with the vertical shaft pin 24 also to be slidable in the
radial direction of the start end wheel 19a.
[0329] Inside the intermediate wheel 92b is arranged a cam, not
shown, which is engaged with the cam follower 25 so as to slide the
cam follower 25 and the vertical shaft pin 24 in the radial
direction of the start end wheel 19a at the predetermined position
and which acts to switch the clamp pieces 20a and 20b of the
gripper 20 to the opened position or closed position thereof. When
the intermediate wheel 92b is rotated and the gripper 20 is moved
so as to oppose to the bottle 1 gripped by the gripper 28 of the
wheel 92a, the clamp pieces 20a and 20b of the gripper 20 grips
bottle neck portion 1a at the lower side of the support ring 5 and
conveys the bottle 1 in the vertically suspended state.
[0330] Furthermore, as shown in FIGS. 15A and 15B, the gripper 20
is provided with horizontal pivot 26 projecting in the
circumferential direction of the start end wheel 19a, and the
gripper 20 is held to the start end wheel 19a through the
horizontal pivot 26. On the other hand, as shown in FIG. 16,
another cam 27 circularly curved with the turning shaft of the
start end wheel 19a being the center of the curvature is also
disposed so that each of the grippers 20 contacts this cam 27. When
intermediate wheel 92b is turned and the gripper 20 receiving the
bottle 1 is turned, the gripper 20 is vertically inverted together
with the bottle 1 with the horizontal pivot 26 being the fulcrum
under the guidance of the cam 27. According to such motion, as
shown in FIGS. 14A and 14B, the bottle 1 is vertically inverted
with the neck portion 1a thereof being directed downward.
[0331] As shown in FIG. 14A, the bottle 1 passing through the
interior of the air rinse section 96 travels in the aseptic water
rinse section 91 with being gripped in the vertical attitude by the
gripper 28 around the start end wheel 92a, and as shown in FIG.
14B, is then inverted in its position by the gripper 20 of the
intermediate wheel 92b. At this time, the hot water nozzle 93 is
inserted into the bottle 1 through the bottle neck portion 1a to
thereby feed the hot water "w" of the aseptic water into the bottle
1. The hot water "w" cleans the inside of the bottle 1 and then
flows out of the bottle 1 from the neck portion 1a thereof. After
the cleaning of the bottle 1 by the hot water "w", the bottle 1 is
again turned to the vertically normal position by the gripper 20 of
the intermediate wheel 92b, is received by the gripper 28 of the
final end wheel 92c, and is then conveyed to the subsequent
beverage filling section 10.
[0332] The hot water "w" is aseptic water of the temperature of
about 60 to 70.degree. C., but it may be of normal temperature.
[0333] As shown in FIG. 16, the beverage filling section 10 is
connected to the aseptic water rinse section 91. The beverage
filling section 10 is also entirely covered with the chamber 10a,
and a partition wall, not shown, is disposed between this chamber
10a and the chamber 91a of the aseptic water rinse section 91. The
partition wall is formed with a bottle passing hole.
[0334] A wheel row coupled with the final end wheel 92c as
travelling means for the bottle 1 on the aseptic water rinse
section side is connected, as shown in FIG. 13, to the inside of
the chamber 10a of the beverage filling section 10.
[0335] More specifically, this wheel row includes six wheels 94a,
94b, 94c, 94d, 94e, 94f, around which a bottle travelling path is
formed.
[0336] Furthermore, grippers 28 similar to those shown in FIG. 4
are arranged around the respective wheels 94a, 94b, 94c, 94d, 94e
and 94f.
[0337] In the chamber 10a of the beverage filling section 10, the
grippers 28 transfer the bottles 1 subsequently from the start end
wheel 94a to the final end wheel 94f while gripping the bottle neck
portions 1a and turning around the respective wheels 94a, 94b, 94c,
94d, 94e and 94f. According to such operation, the bottles 1
continuously travel in the beverage filling section 10 from the
start end wheel 94a toward the final end wheel 94f, and during the
travelling, since the gripper 28 grips the neck portion 1a of the
bottle 1 by the paired clamp pieces 28a and 28b, the bottle 1
travels in the normally vertically suspended attitude.
[0338] The beverage filling machine is disposed in the chamber 10a
of the bottle 1 is filled with the preliminarily sterilized
beverage "a" from the nozzle 95 of the beverage filling machine.
This nozzle 95 is travelled in synchronous with the bottle 1, and
accordingly, a constant amount of beverage "a" fills the bottle 1
during the travelling of the bottle 1 and the nozzle 95.
[0339] Furthermore, a capper is disposed to a predetermined
position around the intermediate wheel 94e on the downstream side
of the beverage filling machine. As shown in FIG. 3O, the cap 2 is
applied by the neck portion 1a of the bottle 1, thus sealing the
bottle 1.
[0340] The bottle 1 filled with the beverage "a" and sealed by the
cap 2 is then released from the gripper 28 of the final end wheel
94f and discharged externally from the beverage filling apparatus
from an outlet of the chamber 10a.
[0341] Incidentally, as shown in FIG. 13, a servo-motor S3 for
driving all the wheels 92a, 92b, 92c in the aseptic water rinse
section 91 so as to be dynamically interlocked with each other is
disposed in the aseptic water rinse section 91, and three
servo-motors S4, S5 and S6 for driving the wheels 94a, 94b, 94c,
94d, 94e and 94f in the beverage filling section 10 so as to be
dynamically interlocked in predetermined combinations thereof are
disposed in the beverage filling section 10. In these servo-motors
S4, S5 and S6, the servo-motor S4 drives the wheels 94a and 94b
disposed on the upstream side of the intermediate wheel 94b for
which the beverage filling machine is provided, the servo-motor S5
drives the intermediate wheel 94c for which the beverage filling
machine is provided, and the servo-motor S6 drives the wheels 94d,
94e and 94f disposed downstream side of the intermediate wheel 94c
for which the beverage filling machine is provided.
[0342] According to the arrangement mentioned above, even if the
respective wheels and grippers of the inspection section 8, the air
rinse section 96, the aseptic water rinse section 91 and the
beverage filling section 10 have the structures different from each
other, the grippers of the respective sections can be driven
synchronously in accordance with the controlling of the
servo-motors S1 to S6, and thus, the bottles 1 can be smoothly
continuously travelled from the molding section 7 toward the
beverage filling section 10.
[0343] Further, in the above second embodiment, although the
molding section 7 is driven by a generally known electric motor,
the wheels and the turntable of the molding section 7 may be also
driven by the servo-motor.
[0344] The function or operation of the beverage filling apparatus
according to the second embodiment will be described hereunder.
[0345] (1) First, the preform 6 such as shown in FIG. 3A is
prepared. The preform 6 is injection-molded through the injection
molding process, and thereafter, is fed into the preform supply
machine 11 of the beverage filling apparatus of this
embodiment.
[0346] The preform 6 is then supplied into the molding section 7 by
means of conveyer 12 of the preform supply machine.
[0347] (2) The preform 6 is conveyed by the conveyer 12 in a
vertically standing position as shown in FIG. 3A is received by the
gripper of the start end wheel 13a continuously rotating in the
molding section 7, and is inverted up-side-down by the gripper of
the intermediate wheel 13b.
[0348] The preform 6 in the inverted attitude is applied to the
mandrel 17 of the first turntable 14a from the neck portion 1a of
the bottle 1.
[0349] The mandrel 17 applied with the preform 6 travels, as shown
in FIG. 3C, while revolving, in the heating chamber 16, and then,
continuously travels in the heating chamber 16, while revolving,
together with the mandrel 17. Thus, the preform 6 can be uniformly
heated to a temperature capable of being subjected to the blow
molding treatment.
[0350] (3) The heated preform 6 is clamped by the blow molding mold
18 as shown in FIG. 3D, and air is blown through the blow nozzle 19
penetrating the mandrel 17. Thus, the bottle 1 is molded in the
mold 18.
[0351] The thus molded bottle 1 is taken out of the mold 18 by
opening the mold 18 together with the mandrel 17, and as shown in
FIG. 3E, is conveyed in the inverted attitude toward the first
turntable 14a through the sixth turntable 14f.
[0352] (4) The bottle 1 held by the mandrel 17 at the first
turntable 14a grips by the gripper 98 of the start end wheel 19a,
as shown in FIG. 3F, in the normally vertical attitude. In this
time, the gripper 98 grips the portion of the bottle 1 above the
support ring 5 of the bottle neck portion 1a. Subsequently, the
bottle 1 is received by the gripper 28, as shown in FIG. 4, of the
final end wheel 19b, and at this time, the gripper 28 grips the
portion of the bottle 1 below the support ring 5 of the bottle neck
portion 1a as shown in FIG. 6.
[0353] (5) The gripper 37 of the start end wheel 36a of the
inspection section 8 grips the portion of the bottle 1 above the
support ring 5 of the bottle neck portion 1a and receives the
bottle 1. This bottle 1 is turned in a state being held by the
gripper 37
[0354] During this turning motion, as shown in FIG. 3G, the shell
portion of the bottle 1 is inspected by the bottle shell portion
inspection means. In this inspection, the image of the bottle shell
portion picked up by the camera 45 is processed by the image
processing device, not shown, and it is discriminated whether any
abnormality such as injury, foreign material, discoloration or like
exists.
[0355] (6) The bottle 1 is transferred to the gripper 28 of the
intermediate wheel 36b from the gripper 37 of the start end wheel
36a, and then, as shown in FIG. 3H and FIG. 6, is turned by the
gripper 28 of the intermediate wheel 36b while being gripped at the
portion below the support ring 5 of the bottle neck portion 1.
[0356] During this turning motion, as shown in FIG. 3H, the
temperature of the bottle 1 is detected by the temperature sensor
46 of the temperature detecting means. In this temperature
detection, if it does not reach 50.degree. C., for example, it is
judged that this bottle 1 is defective product.
[0357] (7) Subsequently, as shown in FIG. 3I, the surface condition
of the support ring 5 of the bottle 1 is inspected by the support
ring inspection means. In this inspection, the image of the upper
face of the support ring 5 picked up by the camera 48 is processed
by the image processing device, not shown, and it is discriminated
whether any abnormality such as injury, foreign material,
discoloration or like exists.
[0358] (8) Subsequent to the inspection of the support ring 5 of
the bottle 1, as shown in FIG. 3J, the surface condition of the
upper face 1d of the bottle neck portion 1a is inspected by the
bottle neck portion upper face inspection means. In this
inspection, the image of the upper face 1d of the bottle neck
portion 1a picked up by the camera 50 is processed by the image
processing device, not shown, and it is discriminated whether any
abnormality such as injury, foreign material, discoloration or like
exists.
[0359] (9) Subsequent to the inspection of the upper face 1d of the
bottle neck portion 1a, as shown in FIG. 3K, the bottom portion of
the bottle 1 is inspected. In this inspection, the image of the
bottle bottom portion picked up by the camera 52 is processed by
the image processing device, not shown, and it is discriminated
whether any abnormality such as injury, foreign material,
discoloration or like exists.
[0360] (10) The bottle 1 subjected to the above respective
inspections is held by the gripper 28 shown in FIG. 8 of the final
end wheel 36c of the inspection section 8. In an event that a
signal representing any abnormality is generated during these
various inspections, the gripper releasing mechanism is operated as
shown in FIG. 9 so that the paired clamp pieces 28a and 28b of the
gripper 28 are operated from the closed state shown with
two-dot-chain line to the opened state shown with solid line, thus
releasing the defective bottle 1.
[0361] According to such operation, the bottle 1 to which any
abnormality such as injury is generated to the shell portion, the
bottom portion, the upper face 1d of the bottle neck portion 1a,
the support ring 5 or the like is removed from the bottle
travelling path. Furthermore, the bottle 1 of a temperature such
that sufficient sterilization cannot be given to the bottle 1 even
if the sterilization by the hydrogen peroxide is effected in the
following sterilizing process is also removed from the bottle
travelling path.
[0362] On the other hand, the good bottle as non-defective product
is conveyed toward the sterilization section 9 through the bottle
removing section because the movable cam 53a is retained at the
position shown in FIG. 9A.
[0363] (11) The bottle 1 as good product is transferred to the
gripper 28 of the start end wheel 58a of the sterilization section
9 from the gripper 28 of the final end wheel 36c of the inspection
section 8, and then transferred to the grippers of the downstream
side wheels and continuously travelled.
[0364] When the bottle 1 as good product is travelled around the
intermediate wheel 58b in the state being gripped by the gripper
28, as shown in FIG. 3L, the bottle 1 passes directly below the
spray tube 59. Accordingly, the condensed mist .alpha. of the
hydrogen peroxide ejected from the spray tube 59 is sprayed toward
the bottle 1 to thereby sterilize the inner and outer surfaces of
the bottle 1. As mentioned above, since only the bottles 1 judged
as good products to which proper heat remains reach, these bottles
1 are properly sterilized by the condensed mist .alpha. of the
hydrogen peroxide and then conveyed downstream side.
[0365] (12) The bottle 1 sterilized by the condensed mist .alpha.
of the hydrogen peroxide is travelled around the intermediate wheel
58c in the manner of being gripped by the gripper 28, and in this
time, as shown in FIG. 3M, the hydrogen gas .beta. and the hot air
.gamma. are blown from the nozzle 64. Accordingly, the inner and
outer surfaces of the bottle 1 are subjected to the air rinsing
treatment to thereby remove the hydrogen peroxide adhering to the
inner and outer surfaces of the bottle 1.
[0366] (13) As shown in FIG. 12, the positive pressure creating
means is disposed on the way of the travelling path from the
molding section 7 to the sterilization section 9 through the
inspection section 8. According to the location of such positive
pressure creating means, extra amounts of the condensed mist
.alpha. of the hydrogen peroxide and the gas .beta. flowing into
the chamber 9a of the sterilization section 9 are exhausted outside
the chamber 9a through the ducts 86 and 89. On the other hand, the
cleaned air flowing into the chamber 8a of the inspection section 8
flows toward the chamber 7a of the molding section 7 and the
atmosphere shutoff chamber 79 so as to prevent the contaminated air
or air containing the hydrogen peroxide from flowing into the
chamber 8a of the inspection section 8.
[0367] Furthermore, even if the air is sucked into the chamber 8a
of the inspection section 8 from the chamber 7a of the molding
section by the travelling of the bottle 1, this air is prevented
from flowing into the chamber 9a of the sterilization section 9 by
the exhaust from the atmosphere shutoff chamber 79, so that the
inside of the sterilization section 9 can be effectively prevented
from being contaminated.
[0368] (14) During the conveyance of the bottle 1 toward the
downstream side of the sterilization section 9 though the
inspection section 8, if any abnormality is generated on the
molding section side and the wheel row on the molding section side
is emergently stopped, as shown in FIG. 7, the piston rod 42a of
the piston-cylinder assembly 42 is contracted so that the paired
clamp pieces 37a and 37b now in closed state are opened by about
180 degrees as shown in FIG. 7. According to this operation, the
interference of the gripper 28 mounted to the final end wheel 19b
of the molding section 7 with the gripper 37 mounted to the start
end wheel 36a of the inspection section 8 can be prevented from
causing.
[0369] Furthermore, since the start end wheel 36a and the following
wheel rows are continuously rotated, the bottle 1 introduced into
the inspection section 8 is continuously travelled toward the
downstream side. Accordingly, the normally molded bottle 1 is
inspected in the inspection section 8, and the bottle 1 passing
through the inspection section 8 is conveyed toward the
sterilization section 9, thus preventing waste bottles 1 from
generating. In addition, even if the molding section 7 stops the
operation, the inspection section 8 and the following sections can
be operated, so that the bottle 1 can be continuously travelled in
the downstream side direction following the sterilization section
9, and hence, the excessive adhesion of the hydrogen peroxide by
the stopping of the bottle 1 in the sterilization section 9 and the
defective sterilization function due to the cooling of the bottle 1
can be effectively prevented. Thus, the only the good bottles 1 can
be filled with the beverage.
[0370] (15) The bottle 1 blown with the condensed mist .alpha. of
the hydrogen peroxide in the sterilization section 9 enters the air
rinse section 96 and is subjected to the air rinsing treatment
around the wheel 58c as shown in FIG. 14A. Accordingly, the
excessive amount of the hydrogen peroxide adhering to the bottle 1
can be removed therefrom.
[0371] (16) The bottle 1 subjected to the air rinsing treatment is
conveyed into the aseptic water rinse section 91 from the gripper
28 of the final end wheel 58e of the air rinse section 96 and then
travelled around the wheels 92a, 92b and 92c in the aseptic water
rinse section 91 from the upstream side toward the downstream side.
The bottle 1 is then inverted up-side-down by the gripper 20 of the
intermediate wheel 92b, and as shown in FIG. 14B, the interior of
the bottle 1 is cleaned with the aseptic hot water "w". Thus, the
excessive hydrogen peroxide adhering to the inner surface of the
bottle 1 can be removed.
[0372] In the case where the air in the air rinse section does not
include the gas .beta. of the hydrogen peroxide, although such
aseptic water rinsing treatment may be eliminated, even in such
case, the aseptic water rinsing treatment may be performed as
occasion demands. The bottle 1 after the cleaning is returned to
the normal vertical position with the bottle neck portion 1a being
directed upward by the inverting movement of the gripper 20.
[0373] (17) The bottle 1 subjected to the aseptic water rinsing
treatment is conveyed to the beverage filling section 10, and at
the time of travelling around the wheel 94c with being gripped by
the gripper 28, a predetermined amount of the beverage "a" is fed
from the nozzle 95 of the beverage filling machine, as shown in
FIG. 3N.
[0374] (18) The bottle 1 filled up with the beverage "a" travels
around the wheel 94e with the neck portion 1a thereof being gripped
by the gripper 28, and during the travelling, the cap 2 is applied
to the neck portion 1a by the capper as shown in FIG. 3O. According
to this operation, the bottle 1 is sealed as beverage package,
which is then conveyed outward the beverage filling apparatus.
[0375] Further, in the embodiment of FIG. 13, it may be possible to
eliminate the air rinse section 96 and directly connect the aseptic
water rinse section 91 to the sterilization section 9. In such
arrangement, the bottle 1 sterilized in the sterilization section 9
is immediately sent to the aseptic water rinse section 91 so as to
be subjected to the hot-water rinsing treatment of the heated
aseptic water. According to this operation, although the
sterilization by the hydrogen peroxide in the sterilization section
9 is relatively difficult, aspergillus spore such as ascomycontina
relatively weak to heat may be sterilized by the aseptic hot water.
Thus, beverage which is liable to be corrupted by the aspergillus
spore can fill the bottle, which is then stored.
Third Embodiment 3
[0376] In this third embodiment, a container or vessel to be
sterilized is a bottle 1 shown in FIG. 20B, which is obtained by
blow-forming the preform 6 formed of PET shown in FIG. 20A. The
preform 6 has a bottomed tubular shape having a mouth portion 1a as
like as the bottle 1.
[0377] This container is sterilized in a sequence shown in FIG.
20.
[0378] First, a preform as shown in FIG. 20A is prepared. The
preform 6 is heated so that an entire temperature of the bottle 1
increased to a uniform temperature range suitable for the molding
of the preform 6, and thereafter, as shown in FIG. 20A, the preform
6 is fed into the mold 18 so as to be molded as a bottle 1.
[0379] A blow-molding (injection) machine is provided with the mold
18 surrounding the preform 6 and the blow nozzle 19 for blowing
gas. The bottle 1 is formed in the mold 18 by blowing gas such as
air from the blow nozzle 19 into the preform 6 of which temperature
is increased to the suitable temperature range in the mold 18.
Thereafter, the mold 18 is opened and the bottle 1 is taken out of
the mold 18.
[0380] In this blow forming process, the temperature of the mold 18
is maintained at substantially constant temperature, which is a
temperature of the bottle 1 at the time of supplying the condensed
mist .alpha. of the hydrogen peroxide into the bottle 1 and is
appropriately set in accordance with substance or material of the
bottle 1 or shape to be desired, and this temperature is, for
example, 60 to 80.degree. C.
[0381] As shown in FIG. 20A, the mold 18 is composed of a mold
upper portion 18a corresponding to the mouth portion 1a of the
bottle 1, a mold central portion 18b corresponding to the shell
portion 1b of the bottle 1 and a mold bottom portion 18c
corresponding to the bottom portion 1c of the bottle 1, and these
mold portions are splittable and are set so as to have temperatures
different from each other. For example, the temperature of the mold
upper portion 18a corresponding to the mouth portion 1a of the
bottle 1 may be set to a temperature lower than those of the mold
central portion 18b and mold bottom portion 18c. Since the mouth
portion 1a of the bottle 1 has already been formed to the preform
6, if the mouth portion 1a is excessively heated, the mouth portion
1a may be deformed. Therefore, such deformation of the mouth
portion 1a can be prevented by setting the temperature of the mold
upper portion 18a contacting the mouth portion 1a to be lower than
those of the other portions, the deformation of the mouth portion
1a may be effectively prevented.
[0382] The molding process of the bottle 1 shown in FIG. 20A is
performed synchronously with the travelling of the mold 18 of the
blow molding machine, the blow nozzle 19 and the preform 6.
However, it may be possible to mold the bottle 1 from the preform 6
at a fixed position by setting the blow forming machine to the
fixed position.
[0383] The thus molded bottle 1 is maintained at a predetermined
temperature by the remaining heat at the molding process by the
mold 18, and during the following travelling at a predetermined
speed, as shown in FIG. 20B, the surface temperature is detected by
the temperature sensors 46, 46. This temperature is a preliminarily
heating temperature for suitably sterilizing the bottle 1, and it
is hence desirable to be more than 50.degree. C. for effectively
achieving the desired sterilizing effect by the hydrogen peroxide
in the following process.
[0384] As the temperature sensors 46, 46, although an infrared ray
thermometer may be utilized, for example, other thermometers may be
also utilized. These temperature sensors 46, 46 are arranged so as
to oppose to the support ring of the mouth portion 1a of the bottle
1 and the bottom portion 1c thereof as shown in FIG. 20B.
[0385] In a case where either one of the temperatures of these two
portions of the bottle 1 detected by the two temperature sensors 46
and 46 does not reach the predetermined temperature, such bottle 1
is removed as defective product. Such defective bottle 1 having a
temperature not reaching the predetermined temperature may be
considered not to be sufficiently sterilized even if the bottle 1
is sterilized by the hydrogen peroxide in the following process. On
the other hand, the bottle 1 of which temperatures of two portions
reach the predetermined temperatures will be considered to be
sufficiently sterilized when the bottle 1 is sterilized by the
hydrogen peroxide in the following process. Such bottle 1 is
continuously travelled as good product toward the sterilization
section so as to be subjected to the sterilization process as shown
in FIG. 20C.
[0386] Further, although the two portions of the bottle 1 mentioned
above opposing to the temperature sensors 46, 46 are portions
liable to cause cold spots, the number of the temperature sensors
to be located is not limited to two and may be increased or
decreased in accordance with the shape and size of the bottle 1,
and a kind of the mold, or like. For example, only one temperature
sensor 46 may be located to the position opposing to the bottle
bottom portion 1c to which cold spot will be liable to be caused
rather than to the portion of the support ring.
[0387] After the molding process, the bottle 1 maintaining the
preheating temperature is travelled at the predetermined speed, and
as shown in FIG. 20C, during this travelling, the condensed mist
.alpha. of the hydrogen peroxide as a sterilizing agent is blown to
thereby sterilize the bottle 1. The bottle 1 of the temperature not
reaching the preheating temperature is removed before the
sterilization process shown in FIG. 20C, so that only the bottle 1
maintaining the predetermined preheating temperature is subjected
to the sterilization process.
[0388] Further, the bottle 1 may be supplied for the sterilization
process as shown in FIG. 20C by preparing a preliminarily molded
bottle 1 without connecting the molding process of the bottle 1 to
the sterilization process. In such case, it is necessary to convey
the bottle 1 for the sterilization process after heating the bottle
1 to the preheating temperature while blowing hot air to the
travelling bottle 1. The surface temperature of the bottle 1 is
measured also by the manner mentioned with reference to FIG. 20B,
and the bottle 1 to which temperature does not reach the
predetermined temperature is removed.
[0389] The condensed mist .alpha. of the hydrogen peroxide is
generated by gasifying the hydrogen peroxide and then condensing
such gasified hydrogen peroxide such as by a mist generating device
61 shown in FIG. 10.
[0390] The bottle 1 is travelled with its mouth portion 1a being
directed upward, and the spray tube 59 is arranged at the
predetermined position above the travelling path, with the opening
of the spray tube 59 being directed to the mouth portion 1a of the
bottle 1. The condensed mist .alpha. of the hydrogen peroxide is
continuously blown out towards the mouth portion 1a of the bottle 1
conveyed along the travelling path from the opening of the spray
tube 59, and the sprayed condensed mist .alpha. of the hydrogen
peroxide flows into the bottle 1 through the mouth portion 1a
thereof and sterilizes the inner surface of the bottle 1 and also
flows out of the bottle 1 to thereby sterilize the outer surface of
the bottle 1.
[0391] The condensed mist .alpha. of the hydrogen peroxide sprayed
from the spray tube 59 adheres by, preferably, an amount of 30
.mu.L/bottle to 150 .mu.L/bottle, and more preferably, an amount of
50 .mu.L/bottle to 100 .mu.L/bottle.
[0392] As mentioned above, it is desirable that the surface
temperature of the bottle 1 at the supply time of the condensed
mist .alpha. of the hydrogen peroxide is more than 50.degree. C.
that is the preheating temperature, and for this purpose, the spray
tube 59 is arranged to the position at which the bottle surface
temperature can be maintained at a temperature more than 50.degree.
C. The surface temperature of the bottle at this time will be
determined on the basis of the heat capacity of the bottle 1, the
atmospheric condition around the bottle 1, the heat amount applied
by the mold 18 and so on. In this embodiment, the bottle travelling
speed from the blow molding machine to the spray tube 59, the mold
temperature at the bottle molding process and so on are set so that
the bottle surface temperature becomes more than 50.degree. C. at
the time of supplying the condensed mist .alpha. of the hydrogen
peroxide.
[0393] Further, the bottle surface temperature at the time of
supplying the condensed mist .alpha. of the hydrogen peroxide is
appropriately set in accordance with substance and shape of the
bottle 1, kind of the sterilizing agent, and so on so as to
suitably sterilize the bottle 1. It may be not necessary to set the
temperature of the entire bottle surface to be more than 50.degree.
C. For example, in a case where the temperatures of the upper
portion 18a of the mold 18 is lowered more than those of the
central portion 18b and lower portion 18c of the mold 18 at the
time of molding the bottle 1, the temperature of the mouth portion
1a of the bottle 1 may become less than 50.degree. C. In such case,
according to the present embodiment, since the condensed mist
.alpha. of high density of the hydrogen peroxide is supplied to the
mouth portion 1a of the bottle 1, the mouth portion 1a can be
suitably sterilized.
[0394] In the sterilization process shown in FIG. 20C, it may be
desired that the bottle travelling path is surrounded by a tunnel
60, and by surrounding the travelling path by the tunnel 60, the
condensed mist .alpha. of the hydrogen peroxide easily adheres to
the outer surface of the bottle 1, thus improving the sterilizing
effect to the bottle outer surface.
[0395] The bottle 1 of which inner and outer surfaces are
sterilized by the condensed mist .alpha. of the hydrogen peroxide
is further travelled toward the air rinse section so as to be
subjected to the air rinsing treatment as shown in FIG. 20D.
[0396] In this air rinsing treatment, the nozzle 64 following the
travelling of the bottle 1 is disposed. The nozzle 64 is inserted
into the bottle 1 through its mouth portion 1a while travelling
together with the bottle 1 at the same speed. Of course, it is
possible for the nozzle 64 to be arranged so as to be directed to
the mouth portion 1a of the bottle 1 without inserting
thereinto.
[0397] The hydrogen peroxide gas .beta. conveyed by the sterilized
and heated hot air is blown into the bottle 1 through the nozzle
64. This hydrogen peroxide gas .beta. is generated by the air rinse
device shown in FIG. 17 and then supplied to the bottle 1.
[0398] The bottle 1 effected with the air rinsing treatment is
travelled for receiving the cleaning process shown in FIG. 20E, but
the cleaning process may be performed as occasion demands.
[0399] In this cleaning process, the bottle 1 is travelled in an
inverted upside-down-state, and the nozzle 7 for cleaning is
inserted into the mouth portion 1a directed downward, and the
heated aseptic water "w" is injected into the bottle 1 through the
nozzle 7. In this manner, the hydrogen peroxide remaining inside
the bottle 1 is washed out.
[0400] Although it is desirable that the aseptic water "w" is
supplied for the cleaning process by being heated to about 60 to
80.degree. C., the aseptic water of normal temperature may be
supplied as occasion demands. The aseptic water supplying time is
appropriately set in accordance with the capacity or shape of the
bottle 1 to, for example, 1 to 10 seconds.
[0401] After the cleaning of the bottle 1 by the aseptic water "w",
the bottle 1 is again inverted to the state of the mouth portion 1a
being directed upward. Thereafter, the cleaned bottle 1 is filled
with inner content, and after the filling of the inner content, the
bottle 1 is sealed by applying the cap, not shown, to the mouth
portion 1a, thus forming a sealed aseptic package.
[0402] Effects attained by the container sterilization method of
the present invention will be compared with effects attained by the
conventional sterilization method as in the following Table 2.
TABLE-US-00002 TABLE 2 H.sub.2O.sub.2mist H.sub.2O.sub.2 adding
Number of bacteria Judgment adhering amount in air adhering on
inner H.sub.2O.sub.2 using amount (gas density) Log surface of
preform amount Sterilization No. (.mu.L/bottle) (mg/L) reduction
10.sup.3 10.sup.4 10.sup.5 (mL/min) performance Total A1 50 0.0
<3.4 170 .largecircle. X .DELTA. A2 100 0.0 6.0 .largecircle.
.largecircle. .largecircle. .largecircle. .largecircle.
.largecircle. .largecircle. .largecircle. 340 X .largecircle.
.DELTA. A3 150 0.0 >6.0 .largecircle. .largecircle.
.largecircle. .largecircle. .largecircle. .largecircle.
.largecircle. .largecircle. .largecircle. 510 X .circleincircle.
.DELTA. B1 50 3.3 6 .largecircle. .largecircle. .largecircle.
.largecircle. .largecircle. .largecircle. .largecircle.
.largecircle. 230 .largecircle. .largecircle. .largecircle. B2 50 5
>6.0 .largecircle. .largecircle. .largecircle. .largecircle.
.largecircle. .largecircle. .largecircle. .largecircle.
.largecircle. 280 .largecircle. .circleincircle. .largecircle.
[0403] In the column "No" in the above Table 2, A1, A2, A3, B1, B2
denotes bottle sample numbers, in which A1, A2 and A3 correspond to
the conventional sterilization method, and B1 and B2 correspond to
the third embodiment of the present invention mentioned above.
[0404] In the Table 2, the column "H.sub.2O.sub.2 Mist Adhering
Amount" represents the hydrogen peroxide mist adhering to the inner
surface of the bottle.
[0405] The column of "H.sub.2O.sub.2 Adding Amount In Air"
represents the gas density of the hydrogen peroxide gas added in
hot air of the air rinse process.
[0406] The column "Log Reduction" represents LRV (Logarithmic
Reduction Value) as to B. subtilis spore.
[0407] The column of "Bacteria Amount Adhering to Preform Inner
Surface" represents the numbers of bacteria adhering to the inner
surfaces of the preforms before the molding of the respective
bottles A1, A2, A3, B1, B2, and symbol [.largecircle.] shows good
sterilization effect and [.cndot.] shows insufficient sterilization
effect.
[0408] In the column of "Judgment", the term "H2O2 Using Amount"
shows the using amount of the hydrogen peroxide and shows the fact
whether this using amount is appropriate or not, in which symbol
[.largecircle.] shows appropriate using amount and [X] shows
excessive using amount.
[0409] In the column of "Sterilization Performance",
[.circleincircle.] shows the sterilizing effect (LRV) being more
than 6, [.largecircle.] shows LRV being 6, and [X] LVR being less
than 6. In the column of "Total", [.largecircle.] shows that both
the using amount and the sterilizing performance are good, and
[.DELTA.] shows that either one of the using amount and the
sterilizing performance is defective.
[0410] As is apparent from the Table 2, according to the
conventional method, the sterilization effect of LRV=6 can be
obtained only by using large amount of the hydrogen peroxide of 340
mL/min. to 510 mL/min. However, according to the method of the
present invention, the sterilization effect LRV=6, which is the
same as that in the conventional method, can be obtained by using
the hydrogen peroxide only of 230 mL/min. to 260 mL/min. That is,
according to the present invention, substantially the same
sterilization effect as that attained in the conventional method
can be obtained only by reducing the using amount of the hydraulic
peroxide to 1/2.about.1/3 of the conventional method.
[0411] The device for performing the method of the third embodiment
has a structure shown in FIG. 21.
[0412] As shown in FIG. 21, this sterilization device is provided
with a preform supply machine 208 for continuously supplying the
bottomed preforms 6 (shown in FIG. 20A) each having a mouth portion
1a at a predetermined interval, a blow molding machine 209, a
bottle sterilizing machine 210 as sterilizing means for sterilizing
the bottle 1 by contacting the hydrogen peroxide condensed mist
.alpha. to the molded bottle 1, and a filling machine 211 as
filling means for cleaning the sterilized bottle 1 and filling the
bottle 1 with content such as beverage and then sealing the bottle
1.
[0413] A bottle conveying path is formed by predetermined conveying
means along a line between the preform supplying machine 208 and
the filling machine 211, and on the conveying path, grippers 28
(FIG. 17) and other members for holding and conveying the preforms
6 and the bottles 1 are disposed.
[0414] The preform supplying machine 208 is provided with a preform
conveyer 212 for subsequently supplying the preforms 6 to the blow
molding machine 209 at predetermined interval. The preforms 6 are
fed to the blow molding machine 209 through the preform conveyer
212.
[0415] The blow molding machine 209 a heating section 213 for
heating the preform 6 conveyed by the preform conveyer 212 and a
molding section 214 for heating and forming the heated preform 6
into a bottle 1.
[0416] Inside the blow molding machine 209, there is conveying
means for receiving the preform 6 at the final end portion of the
preform conveyer 212 and molding the preform into the bottle 1, and
then conveying the bottle 1 to the succeeding bottle sterilizing
machine 210, and on this conveyer path, the heating section 213,
the molding section 214 and so on are disposed.
[0417] The conveying means is provided with a first row of wheels
215, 216, 217, 218 for conveying the preform 6 from the final end
portion of the preform conveyer 212 to the heating section 213, a
conveyer 219 for conveying the preform 6 within the heating section
213, and a second row of wheels 220, 221, 222, 217 for receiving
the heated preform 6 from the conveyer 219 and feeding the preform
to the molding section 214, in which the preform 6 is molded into
the bottle 1, and then feeding the molded bottle 1 to the
subsequent sterilizing machine 210. The wheel 217 may be commonly
utilized between the first wheel row of wheels 215, 216, 217, 218
and the second wheel row of wheels 220, 221, 222, 217.
[0418] The preform 6 is fed into the blow molding machine 209 by
the preform conveyer 212, and thereafter, is transferred to the
conveyer 219 through the first wheel row of wheels 215, 216, 217,
218, and according to the travelling of the conveyer 219, the
preform 6 is reciprocally moved in the seating section 213. A
heater, now shown, is provided for the wall portion of the heating
section 213, so as to heat the preform 6 conveyed by the conveyer
219. The preform 6 heated in the heating section 213 is received by
the second wheel row of the wheels 220, 221, 222, 217 and then is
transferred to the molding section 214.
[0419] The molding section 214 is provided with a mold 18 (FIG.
20A) for molding the heated preform 6 into the bottle 1 and a blow
nozzle 19 (FIG. 20A) blowing gas into the heated preform 6.
[0420] The mold 18 is composed of, as shown in FIG. 20A, the mold
upper portion 18a for molding the mouth portion 1a of the bottle 1,
the mold central portion 18b for molding the shell portion 1b of
the bottle 1, and the mold bottom portion 18c for molding the
bottom portion 1c of the bottle 1, and the bottle 1 is formed in
the mold 18 by blowing gas such as air into the preform through the
blow nozzle 19. The mold 18 molds the bottle 1 from the preform 6
while being moved together with the preform 6 in the
circumferential direction of the wheel 221.
[0421] The preform 6 is heated by the heating section 213 of the
preform supplying machine 208 and cooled at the time of being
molded into the bottle 1 by the mold 18 of the blow molding machine
209. The bottle 1, however, discharged from the mold 18 is
travelled around the wheels 222 and 217 while keeping the
preliminary molding temperature by the remaining heat at the
molding time.
[0422] A temperature inspection device 238 is provided to a portion
between the molding section 214 of the blow molding machine 209 and
the subsequent bottle sterilizing machine 210, and a wheel row
including wheels 223, 224, 225 is disposed within the temperature
inspection device 238.
[0423] The temperature sensors 46, 46 are arranged to the outer
peripheral portion of the wheel 223 contacting the wheel 217 as
shown in FIG. 20B. A discharge conveyer 295 such as air conveying
device is connected to the downstream side wheel 225 contacting the
wheel 223 through the intermediate wheel 224. The bottle 1, which
is judged not to reach the preliminary molding temperature by the
temperature sensors 46, 46 is discharged outside the conveying path
from the discharge conveyer 295. On the other hand, the bottle 1,
which is judged to reach the preliminary molding temperature by the
temperature sensors 46, 46 is successively travelled along the
conveying path and fed to the subsequent bottle sterilizing machine
210.
[0424] The bottle sterilizing machine 210 is further provided with
a third wheel row including wheels 226, 227 as means for conveying
the bottle 1 subjected to the temperature inspection as mentioned
above and the spray tube 59 as condensed mist supply means for
supplying the hydrogen peroxide condensed mist .alpha. as the
sterilizing agent to the bottle 1.
[0425] One or more than one spray tubes 59 may be disposed, and are
fixed to predetermined positions along the peripheries of the
predetermined wheels in the third wheel row of wheels 226 and 227.
In the illustrated embodiment, although the spray tube 59 is
disposed around the final end wheel 227, the spray tube 59 may be
disposed around the other wheel.
[0426] The condensed mist .alpha. is generated by condensing
hydrogen peroxide sprayed and heated by the mist generating device
61 shown in FIG. 10. The bottle 1 is conveyed around the wheel 227
with the mouth portion 1a being directed downward, and lower end of
the spray tube 59 is opened toward the mouth portion 1a of the
bottle 1. The hydrogen peroxide condensed mist .alpha. is
continuously brown out toward the mouth portion 1a of the bottle 1
from the lower end opening of the spray tube 59. The hydrogen
peroxide condensed mist .alpha. is flown into the bottle 1 through
the mouth portion 1a of the travelling bottle 1 and sterilizes the
inner surface of the bottle 1, and the other hydrogen peroxide
condensed mist .alpha. also sterilizes the outer surface of the
bottle 1.
[0427] The amount of the hydrogen peroxide condensed mist .alpha.
discharged from the spray tube 59 and adhering to the bottle 1 is
that mentioned above.
[0428] The bottle 1 to which the hydrogen peroxide condensed mist
.alpha. is supplied through the spray tube 59 is conveyed to the
succeeding filling machine 211 after the appropriate sterilization
process.
[0429] The filling machine 211 includes fourth wheel row including
wheels 229, 230, 231, 232, 234, 235, 236 as means for conveying the
bottles 1 sterilized in the sterilizing machine 210. An air rinse
section 239 for performing the air-rinsing treatment to the bottle
1 to which the hydrogen peroxide condensed mist .alpha. was
supplied, a cleaning section 240 for cleaning the bottle 1 after
the air-rinsing treatment, a filler 241 for filling the cleaned
bottle 1 with inner content, and a capper 242 for applying a cap,
not shown, to the bottle 1 after being filled with the content and
then sealing the bottle 1 are disposed in the described order along
the fourth wheel row.
[0430] The air rinse section 239 is provided with the nozzle 64
(FIG. 20D) around the wheel 229. The sterilized hot air and the
hydrogen peroxide gas .beta. are blown into the bottle 1 through
the nozzle 64 (see FIG. 2D).
[0431] A plurality of nozzles 64 are arranged so as to correspond
to the bottles 1 (1:1) conveyed around the wheel 229, and as shown
in FIG. 17, the nozzles 64 are attached to the periphery of the
wheel 229 and moved integrally with the bottle 1 in the
circumferential direction of the wheel 229.
[0432] In the illustration of FIG. 17, although the nozzles 64
serve to blow the sterilized hot air .gamma. and the hydrogen
peroxide gas .beta. into the bottles 1 from the position outside
the bottles 1, the respective nozzles 64 may be disposed so as to
be vertically movable and inserted into the bottles 1, as shown in
FIG. 20D, when the hot air .gamma. and the hydrogen peroxide gas
.beta. are blown into the bottles 1.
[0433] The hot air .gamma. and the hydrogen peroxide gas .beta.
from the nozzles 64 may be generated by the manner mentioned with
reference to FIG. 17.
[0434] As mentioned hereinabove, by blowing the sterilized hot air
.gamma. and the hydrogen peroxide gas .beta. into the bottle 1 to
thereby perform the air rinsing treatment, the bottle 1 can be
heated from its inside, and the sterilization effect by the
hydrogen peroxide condensed mist .alpha. and the hydrogen peroxide
gas .beta. can be enhanced. In addition, a portion such as bottom
portion 1c of the bottle 1, which may be insufficiently sterilized
by the hydrogen peroxide condensed mist .alpha. supplied from the
spray tube 59, can be also surely sterilized by the hydrogen
peroxide gas .beta. contained in the hot air .gamma..
[0435] Further, the time period for blowing the hot air .gamma. and
the hydrogen peroxide gas .beta. will be determined in such a
manner that the hydrogen peroxide condensed mist .alpha. floating
inside the bottle 1 can be completely discharged and the defective
sterilization by the condensed mist .alpha. can be compensated for,
and for example, for 20 seconds.
[0436] The cleaning section 240 is provided with an inverting
mechanism, not shown, disposed around the wheel 231 for vertically
inverting the bottle 1 and a nozzle 7 (FIG. 20E) for supplying the
heated aseptic water to the bottle 1. A plurality of nozzles 7 are
arranged around the wheel 231 so as to correspond to the bottles 1
(1:1) conveyed by the wheel 231, and the nozzles 7 are moved
integrally with the bottles 1, respectively. The cleaning section
240 is disposed as occasion demands, and hence, it may be
eliminated in location.
[0437] Further, since conventional filler and capper are utilized
as the filler 241 and the capper 242, the descriptions thereof will
be eliminated herein.
[0438] Incidentally, this sterilization device is surrounded by a
chamber 243, and the interior of this chamber 243 is sectioned into
an aseptic zone, non-aseptic zone, and a gray zone positioned
intermediately between the aseptic zone and non-aseptic zone. The
preform supplying machine 208, the molding machine 209 and the
temperature inspection section 238 are arranged in the non-aseptic
zone, the bottle sterilizing machine 210 is arranged in the gray
zone, and the filling machine 211 is arranged in the aseptic zone,
respectively.
[0439] Hereunder, the operation of the sterilization device will be
explained with reference to FIGS. 1 and 2.
[0440] First, the preform 6 is fed into the blow molding machine
209 by the preform conveyer 212. The preform 6 conveyed into the
blow molding machine 209 is conveyed toward the heating section 213
through the first wheel row of the wheels 216, 217, 218.
[0441] The preform 6 in the heating section 213 is conveyed by the
conveyer 219, and during the conveyance, is heated such that the
entire temperature of the preform 6 increases to the temperature
range suitable for the molding.
[0442] The preform 6 heated in the heating section 213 is conveyed
by the second wheel row of the wheels 220, 221 toward the molding
section 214, in which during the conveyance, the preform 6 is
molded by the mold 18 and the blow nozzle 19 which are moved
together with the preform 6 (refer to FIG. 20A).
[0443] In the molding section 214 of the sterilization device, the
preform 6 is molded by the mold 18, which is maintained at a
predetermined temperature. This predetermined temperature is
appropriately set in accordance with the bottle temperature, bottle
substance, bottle shape at the time of supplying the hydrogen
peroxide condensed mist .alpha. to the bottle 1 mentioned
hereinafter, for example, to 60 to 80.degree. C.
[0444] The molded bottle 1 is transferred from the second wheel row
of wheels 221, 222, 217 to the 223, 224, 225 of the temperature
inspection section 238, and during the travelling around the wheel
223, it is judged whether the surface temperature of the bottle 1
reaches the predetermined preliminarily heating temperature or not,
and in the case where the temperature of the bottle 1 does not
reach the predetermined preliminarily heating temperature, such
bottle 1 is discharged as defective product from the wheel 225 by
the discharge conveyer 295 outside the conveying path, and on the
other hand, in the case where the temperature of the bottle 1
reaches the predetermined preliminarily heating temperature, such
bottle 1 is continuously travelled around the wheel 226 as good
product.
[0445] The bottle 1 judged to be good product is transferred to the
third wheel row of the wheels 226, 227, by which the bottle 1 is
travelled into the sterilizing machine 210.
[0446] The predetermined amount of the hydrogen peroxide condensed
mist .alpha. is supplied through the spray tube 59 into the bottle
1 in the bottle sterilizing machine (FIG. 20B), and during the
conveyance of the bottle 1, the hydrogen peroxide condensed mist
.alpha. is continuously supplied. For this purpose, the hydrogen
peroxide condensed mist .alpha. is blown for several seconds to the
inner and outer surfaces of the bottle 1 during the passing of the
bottle 1 under the spray tube 59 by the rotation of the wheel.
Since the surface temperature of the bottle 1 reaching the bottle
sterilizing machine 210 is maintained more than 50.degree. C., the
bottle 1 can be appropriately sterilized by the hydrogen peroxide
condensed mist .alpha..
[0447] The sterilized bottle 1 is transferred from the third wheel
row of the wheels 226, 227 to the fourth wheel row of the wheels
229, 230, 231, 232, 233, 234, 235, 236 and then travelled in the
filling machine 211 by the fourth row of wheels.
[0448] In the filling machine 211, the bottle 1 is first conveyed
to the air rinse section 239, in which the nozzle 64 is inserted
into each of the bottles 1 around the wheel 229, and the hot air
.gamma. and the hydrogen peroxide gas .beta. are supplied into the
bottle 1 to thereby perform the air rinsing treatment (FIG.
20D).
[0449] After the air rinsing treatment, the bottle 1 is conveyed to
the cleaning section 240, in which the bottle is vertically
inverted around the wheel 231 by the inverting mechanism, not
shown, and the nozzle 7 is inserted into the bottle 1 from the
downwardly directed mouth portion 1a thereof to thereby supply the
heated aseptic water "w" into the bottle 1 through the nozzle 7
(FIG. 20E). In this manner, the hydrogen peroxide remaining in the
bottle 1 is washed out. Although the aseptic water "w" has a
temperature of 60 to 70.degree. C., it may be normal
temperature.
[0450] After the cleaning by the aseptic water "w", the bottle 1 is
again vertically inverted so that the mouth portion 1a thereof is
directed upward.
[0451] This cleaning section 240 may be eliminated as occasion
demands.
[0452] Thereafter, the bottle 1 is filled with the content such as
beverage, which was subjected to the sterilization treatment, by
the filler 241. The bottle 1 with the inner content is applied with
the cap, not shown, by the capper 242 for sealing, and then
discharged from an outlet of the chamber 243. As mentioned above,
since the filler 241 and the capper 242 are known ones,
explanations of the method of filling the bottle with the content
and the method of sealing the bottle will be omitted herein.
Fourth Embodiment 4
[0453] As shown in FIG. 22, a bottle sterilization apparatus of
this fourth embodiment is provided with a preliminarily heating
device 296 in place of the preform supply machine 208 and the blow
molding machine 209 of the sterilization apparatus of the third
embodiment.
[0454] A wheel row including wheels 276, 277, 278 forming a bottle
conveying path is disposed to a position corresponding to the
preliminarily heating device 296.
[0455] In this wheel row, an air conveying device 279, for example,
is connected to the most upstream side wheel 276 and the molded
bottles 1 are subsequently supplied. The bottles 1 are conveyed
around the wheels 276, 277 and 278 by being gripped by grippers
similar to those 28 shown in FIG. 4.
[0456] Box members 280, each in form of tunnel through which the
bottles pass, are provided around the wheels 276, 277 and 278,
respectively. Hot air is supplied to each box member 280 from a hot
air supply device of the structure similar to that shown in FIG.
17. The hot air blown into the box member 280 is directed toward
the bottle 1 passing through the box member 280 to thereby
preliminarily heat the bottle 1. According to this preliminarily
heating, the bottle temperature increases to a temperature more
than 50.degree. C.
[0457] Thereafter, although the bottles 1 are conveyed toward the
bottle sterilizing machine 219 to be subjected to the sterilization
treatment, before this conveyance, the bottles 1 are inspected in
the temperature inspection section 238 whether the surface
temperature of the bottle 1 reaches the predetermined preliminarily
heating temperature.
[0458] The temperature inspection section 238 has a structure
similar to that of the third embodiment and is provided with the
wheel row of wheels 223, 224, 225, 226 interposed between the wheel
278 of the preliminarily heating device 296 and the wheel 227 of
the bottle sterilizing machine 210. The bottles 1 preliminarily
heated by the preliminarily heating device 296 are travelled around
the wheel 223, and during this travelling, it is discriminated
whether the surface temperature of the bottle 1 reaches the
predetermined preliminarily heated temperature. The bottle 1 of
which surface temperature does not reach the predetermined
preliminarily heated temperature is discharged outside the
conveying path by the discharge conveyer 295 from the wheel 225 as
defective product. On the contrary, the bottle 1 of which surface
temperature reaches the predetermined preliminarily heated
temperature is successively travelled as a good product around the
wheel 226.
[0459] Further, the location of such temperature inspection section
238 is optional and may be omitted on demand.
[0460] The bottle 1 subjected to the temperature inspection is
conveyed toward the bottle sterilizing machine 210. Since the
bottle 1 is preliminarily heated, the sterilizing effect by the
hydrogen peroxide condensed mist .alpha. supplied in the
sterilizing machine 210 can be improved.
[0461] The structures of the sterilization apparatus downstream
side of this bottle sterilizing machine 210 are substantially the
same as those in the sterilization apparatus of the third
embodiment, so that the details thereof will be omitted herein.
Fifth Embodiment 5
[0462] As shown in FIG. 23, a bottle sterilization apparatus of
this fifth embodiment is provided with a preliminarily heating
device 297 having a structure different from that of the
preliminarily heating device 296 of the fourth embodiment mentioned
above.
[0463] That is, another wheel 281 is provided in place of the wheel
277 of the fourth embodiment, and a hot air supplying device of the
structure similar to that shown in FIG. 11 is arranged around this
wheel 281.
[0464] The bottle temperature increases to a temperature more than
50.degree. C. by this hot air supplying device.
[0465] Thereafter, although the bottles 1 are conveyed toward the
bottle sterilizing machine 210 to be subjected to the sterilization
treatment, before this conveyance, the bottles 1 are inspected in
the temperature inspection section 238 whether the surface
temperature of the bottle 1 reaches the predetermined preliminarily
heating temperature.
[0466] The temperature inspection section 238 has a structure
similar to that of the third embodiment and is provided with the
wheel row of wheels 223, 224, 225, 226 interposed between the wheel
278 of the preliminarily heating device 296 and the wheel 227 of
the bottle sterilizing machine 210.
[0467] The bottles 1 preliminarily heated by the preliminarily
heating device 296 are travelled around the wheel 223, and during
this travelling, it is discriminated whether the surface
temperature of the bottle 1 reaches the predetermined preliminarily
heated temperature. The bottle 1 of which surface temperature does
not reach the predetermined preliminarily heated temperature is
discharged outside the conveying path by the discharge conveyer 295
from the wheel 225 as defective product. On the contrary, the
bottle 1 of which surface temperature reaches the predetermined
preliminarily heated temperature is successively travelled as a
good product around the wheel 226.
[0468] Further, the location of such temperature inspection section
238 is optional and may be omitted on demand.
[0469] The bottle 1 subjected to the temperature inspection is
conveyed toward the bottle sterilizing machine 210. Since the
bottle 1 is preliminarily heated, the sterilizing effect by the
hydrogen peroxide condensed mist .alpha. supplied in the
sterilizing machine 210 can be improved.
[0470] The structures of the sterilization apparatus downstream
side of this bottle sterilizing machine 210 are substantially the
same as those in the sterilization apparatus of the third
embodiment, so that the details thereof will be omitted herein.
[0471] Furthermore, it is to be noted that the present invention is
not limited to the described embodiments and many other changes and
modifications may be made.
[0472] For example, the container to which the beverage filling
apparatus of the present invention is applicable is not limited to
a PET bottle, and the present invention may be applied to various
resin containers. In addition, as the beverage, liquids containing
particular material, agglomerate material or like, or high
viscosity material other than simple liquid may fill the container.
Furthermore, the bottle may be molded by direct blow molding
method, injection molding method without being limited to the
injection blow molding method.
[0473] Still furthermore, the cleaning of the bottle by the aseptic
water is not limited to a method performed while flowing the
aseptic water. The conveying means for conveying the bottles is not
limited to the wheel conveying device mentioned above, and various
conveying devices capable of conveying the bottles at a
predetermined conveying speed in accordance with the bottle molding
order, such as air conveying device, belt conveying device, bucket
conveying device and the like may be utilized.
[0474] Furthermore, the sterilizing method and sterilizing devices
utilized in the beverage filling method and beverage filling
apparatus according to the present invention may take the following
modes or examples.
[0475] (1) Mode 1
[0476] This mode 1 for the sterilization method includes: removing
a container having temperature not reaching predetermined
temperature by performing the container temperature inspection
while travelling the container; blowing the hydrogen peroxide
condensed mist toward the mouth portion of the container through
the spray tube disposed at the predetermined position while
travelling the container having the predetermined temperature; and
blowing the hydrogen peroxide gas into the container through the
nozzle while moving the nozzle so as to follow the mouth portion of
the container.
[0477] According to this mode 1, only the containers of which
temperature reaches a predetermined temperature can be travelled
toward the sterilization section to be subjected to the suitable
sterilization treatment by the hydrogen peroxide, and accordingly,
it becomes possible to prevent the content from filling the
container which is insufficiently sterilized. Furthermore, since
the hydrogen peroxide gas is supplied after the supplying of the
hydrogen peroxide condensed mist, the container can be suitably
sterilized without increasing the flow rate and consuming amount of
the hydrogen peroxide and the hydrogen peroxide condensed mist even
if the travelling speed of the container is increased for enhancing
the productivity of the aseptic packages.
[0478] (2) Mode 2
[0479] This mode 2 includes a container sterilization method in
which preliminarily heating is performed by remaining heat at the
molding time of the container in the container sterilization method
of the mode 1.
[0480] According to this mode 2, the container can be preheated
without additionally preparing a heat source for preliminary heat,
and therefore, the heat energy becomes effectively usable.
[0481] (3) Mode 3
[0482] This mode 3 includes a container sterilization method in
which the hydrogen peroxide gas is a gas obtained by heating and
gasifying the hydrogen peroxide condensed mist by hot air in the
container sterilization method of the mode 1 or mode 2.
[0483] According to this mode 3, the hydrogen peroxide gas having a
suitable density can be supplied to the container without being
condensed, and therefore, the hydrogen peroxide can be prevented
from falling down into the container and the container can be
sufficiently sterilized.
[0484] (4) Mode 4
[0485] This mode 4 includes a container sterilization method in
which the container is cleaned by the aseptic water after the
blowing of the hydrogen peroxide gas into the container in the
container sterilization method described in any one the mode 1,
mode 2 or mode 3.
[0486] According to this mode 4, the hydrogen peroxide used for the
sterilization can be effectively removed from the container.
[0487] (5) Mode 5
[0488] This mode 5 includes the container sterilization apparatus
provided with conveying means for conveying the container along the
predetermined path, and including; preliminarily heating means for
preliminarily heating the container travelling along the conveying
path to a predetermined temperature; a temperature sensor for
inspecting whether a temperature of the preliminarily heated bottle
reaches the predetermined temperature; removing means for removing
the container of which temperature does not reach the predetermined
temperature from the conveying path; a spray tube for blowing
hydrogen peroxide condensed mist from a predetermined position
toward a mouth portion of the container of which temperature
reaches the predetermined temperature; and a nozzle through which
the hydrogen peroxide gas is blown into the container while
following the container travelling along the conveying path, the
above means and members being arranged along the conveying
path.
[0489] According to this mode 5, only the container of which
temperature reaches the predetermined temperature is travelled
toward the sterilization section in which the container can be
appropriately sterilized by the hydrogen peroxide, and accordingly,
it becomes possible to prevent the content from filling the
container which is insufficiently sterilized. Furthermore, since
the hydrogen peroxide gas is supplied after the supplying of the
hydrogen peroxide condensed mist, the container can be suitably
sterilized without increasing the flow rate and consuming amount of
the hydrogen peroxide and the hydrogen peroxide condensed mist (M)
even if the travelling speed of the container is increased for
enhancing the productivity of the aseptic packages.
[0490] (6) Mode 6
[0491] This mode 6 includes the container sterilization apparatus
provided with the container molding machine disposed upstream side
of the spray tube of the conveying path commonly serves as the
preliminarily heating means in the container sterilization
apparatus described in the above mode 5.
[0492] According to this mode 6, the preliminarily hating utilizes
the remaining heat in the container molding process, and
accordingly, the energy can be effectively utilized without
separately preparing a heat source for the preliminary heating.
[0493] (7) Mode 7
[0494] This mode 7 includes the container sterilization apparatus
provided with the container preliminarily hating device on the
upstream side of the spray tube in the container sterilization
apparatus described in the above mode 5.
[0495] According to this mode 7, the preliminary heating of the
container can be surely performed.
[0496] (8) Mode 8
[0497] This mode 8 includes the container sterilization apparatus,
in which the hydrogen peroxide gas is generated by heating the
hydrogen peroxide condensed mist with hot air, in the container
sterilization apparatus described in any one of the above modes 5
to 7.
[0498] According to this mode 8, the hydrogen peroxide gas with
proper density can be supplied to the container without being
condensed, and therefore, the container can be suitably sterilized
while preventing the hydrogen peroxide from dropping in the
container.
[0499] (9) Mode 9
[0500] This mode 9 includes the container sterilization apparatus
provided with the cleaning means for cleaning the interior of the
container by the aseptic water on the downstream side of the nozzle
for blowing the hydrogen peroxide gas, in the container
sterilization apparatus described in any one of the above modes 5
to 8.
[0501] According to this mode 9, the hydrogen peroxide utilized for
the sterilization can be effectively removed from the
container.
* * * * *