Sterile filling system and method

Abstract

The invention relates to a sterile filling system and method. The sterile filling system comprises a sterile filling chamber (1), a sterile transfer chamber (2) and a vaporized hydrogen peroxide generator (3), the sterile filling chamber (1) comprises a sterile operation table (11) and a filling machine (12) arranged on the sterile operation table (11); the sterile transfer chamber (2) comprises a bracket (21) for placing a packing material to be sterilized, an air inlet (22) communicated with the vaporized hydrogen peroxide generator (3) and an opening and closing door (23) capable of communicating the sterile transfer chamber (2) with the sterile filling chamber (1). Compared with the prior art, the method has the advantages that sterilization and sterile transfer of the packing material can be realized, and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of filling equipment, and in particular to an aseptic filling system and method. Background Art

[0002] Aseptic filling refers to filling in a sterile environment, which mainly involves filling sterilized liquid products into sterile packaging containers under sterile conditions and sealing them to ensure that the products have a long shelf life without refrigeration. Summary of the Invention

[0003] The purpose of the present invention is to provide an aseptic filling system and method to achieve sterilization and aseptic transfer of packaging materials.

[0004] The object of the present invention can be achieved by the following technical solutions: an aseptic filling system, comprising an aseptic filling chamber, an aseptic transfer chamber and a vaporized hydrogen peroxide generator;

[0005] The aseptic filling room includes an aseptic operating table and a filling machine arranged on the aseptic operating table;

[0006] The aseptic transfer chamber comprises a bracket for placing packaging materials to be sterilized, an air inlet communicated with a vaporized hydrogen peroxide generator, and an opening and closing door capable of communicating the aseptic transfer chamber with the aseptic filling chamber.

[0007] Preferably, the sterile operating table is a vertical flow sterile operating table, comprising a base, a purification chamber and a purification component arranged in sequence from bottom to top;

[0008] The upper part of the clean room is connected to the purification component, the filling machine is arranged on the work surface in the clean room, the side of the clean room can be connected to the sterile transfer room, and an ultraviolet lamp is also arranged in the clean room.

[0009] Further preferably, the purification component includes a primary filter, a first fan, and a first high-efficiency filter arranged in sequence from top to bottom.

[0010] Further preferably, an operating glove opening is opened on the wall surface of the clean room.

[0011] Further preferably, an ozone generator is provided in the purification chamber.

[0012] Preferably, the filling machine includes a material conveying pipe, a sterile temporary storage tank and a material filling pipe;

[0013] The aseptic temporary storage tank is connected to a material conveying pipe and a material filling pipe. The material conveying pipe is connected to a material inlet. A filling port and a filling control valve are provided on the material filling pipe.

[0014] Further preferably, the sterile temporary storage tank is also connected to a temporary storage tank overflow pipe.

[0015] Further preferably, the material filling pipe is connected to a sterilization reflux pipe.

[0016] Preferably, the aseptic transfer chamber comprises a box body, a bracket is arranged in the box body, an air inlet is arranged on the top of the box body, and an opening and closing door is arranged on the side of the box body close to the aseptic filling chamber.

[0017] Further preferably, the opening and closing door is an up and down sliding door.

[0018] Further preferably, the box body is provided with a second fan and a second high efficiency filter between the air inlet and the bracket.

[0019] Further preferably, the box body is further provided with an air outlet, which is arranged at the bottom of the box body, and the box body is cyclically connected to the vaporized hydrogen peroxide generator through the air inlet, the air outlet and the delivery pipeline.

[0020] Preferably, the vaporized hydrogen peroxide generator includes a gas delivery pipeline and a hydrogen peroxide storage tank connected to the gas delivery pipeline.

[0021] Further preferably, the hydrogen peroxide storage tank is filled with a hydrogen peroxide aqueous solution with a concentration of 30-40 wt%.

[0022] Further preferably, a heating component and an atomization component are provided on the gas delivery pipeline.

[0023] More preferably, the atomizing assembly includes an atomizing nozzle disposed in the gas delivery pipeline, and the atomizing nozzle is connected to the compressed air delivery pipeline and the hydrogen peroxide storage tank.

[0024] Preferably, a peristaltic pump is provided between the hydrogen peroxide storage tank and the atomizing nozzle.

[0025] Preferably, the aseptic filling system further comprises a control mechanism connected to the aseptic filling chamber, the aseptic transfer chamber and the vaporized hydrogen peroxide generator.

[0026] Further preferably, the control mechanism includes a PLC controller.

[0027] An aseptic filling method, performed using the above system, comprises the following steps:

[0028] S1: Place the packaging material to be sterilized on the bracket in the sterile transfer room;

[0029] S2: Start the vaporized hydrogen peroxide generator and introduce vaporized hydrogen peroxide into the sterile transfer chamber through the air inlet to sterilize the packaging material;

[0030] S3: Transfer the sterilized packaging material to the sterile operating table in the sterile filling room and fill it through the filling machine.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] 1. The present invention can achieve packaging material sterilization and aseptic transfer through the coordinated arrangement of an aseptic filling chamber, an aseptic transfer chamber, and a vaporized hydrogen peroxide generator;

[0033] 2. The present invention uses vaporized hydrogen peroxide dry sterilization, which has the ability to kill various microorganisms such as bacteria, fungi, and viruses at room temperature. Compared with ozone and formaldehyde gas, it has better sterilization ability, less residue, and no toxic byproducts;

[0034] 3. The present invention has good sterilization effect and can achieve a 6-log sterilization effect;

[0035] 4. The aseptic filling room of the present invention processes the external air through the cooperation of components such as primary filter, fan, high efficiency filter, etc., so that the cleanliness level in the filling room can reach Class 100. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 Schematic diagram of the structure of the aseptic filling system of the present invention;

[0037] Figure 2 This is a schematic structural diagram of the aseptic filling chamber of the present invention;

[0038] Figure 3 It is a front view of the sterile transfer chamber of the present invention;

[0039] Figure 4 is a side view of the sterile transfer chamber of the present invention;

[0040] Figure 5 Schematic diagram of the structure of the vaporized hydrogen peroxide generator of the present invention;

[0041] Figure 6 The working principle of the vaporized hydrogen peroxide generator of the present invention is Figure 1 ;

[0042] Figure 7 The working principle of the vaporized hydrogen peroxide generator of the present invention is Figure 2 ;

[0043] In the figure: 1- Aseptic filling room, 11- Aseptic operating table, 111- UV lamp, 112- Primary filter, 113- First fan, 114- First HEPA filter, 115- Operating glove port, 116- Ozone generator, 117- Lighting lamp, 12- Filling machine, 121- Material conveying pipe, 122- Aseptic temporary storage tank, 123- Material filling pipe, 124- Material inlet, 125- Filling control valve, 126- Temporary storage tank overflow pipe, 127- Sterilization return pipe, 2- Aseptic transfer room, 21- Bracket, 22- Air inlet, 23- Opening and closing door, 24-housing, 25-second fan, 26-second HEPA filter, 27-gas outlet, 3-vaporized hydrogen peroxide generator, 31-gas delivery pipeline, 32-hydrogen peroxide storage tank, 33-atomizing nozzle, 34-compressed air delivery pipeline, 35-peristaltic pump, 36-regeneration heater, 37-atomizing heater, 38-three-way valve, 39-compressed air flow regulating valve, 310-discharge valve, 311-variable frequency high-pressure fan, 312-dehumidification cracking catalyst, a-packaging material, A-air carrying vaporized hydrogen peroxide, B-clean air, C-compressed air. DETAILED DESCRIPTION

[0044] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0045] Example 1

[0046] An aseptic filling system, such as Figure 1 As shown, it includes a sterile filling chamber 1, a sterile transfer chamber 2 and a vaporized hydrogen peroxide generator 3.

[0047] The aseptic filling room 1 includes an aseptic operating table 11 and a filling machine 12 , and the aseptic transfer room 2 includes a bracket 21 , an air inlet 22 and an opening and closing door 23 .

[0048] Specifically, the filling machine 12 is set on the sterile operating table 11, the bracket 21 is used to place the packaging material a to be sterilized, the air inlet 22 is connected to the vaporized hydrogen peroxide generator 3, and is used to introduce vaporized hydrogen peroxide into the sterile transfer chamber 2. When the opening and closing door 23 is opened, the sterile transfer chamber 2 can be connected to the sterile filling chamber 1.

[0049] When using the system of this embodiment for aseptic filling, the following steps are included:

[0050] S1: Place the packaging material a to be sterilized on the bracket 21 of the sterile transfer room 2;

[0051] S2: Start the vaporized hydrogen peroxide generator 3 and introduce vaporized hydrogen peroxide into the sterile transfer chamber 2 through the air inlet 22 to sterilize the packaging material a;

[0052] S3: The sterilized packaging material a is transferred to the aseptic operating table 11 of the aseptic filling room 1 and filled by the filling machine 12.

[0053] Example 2

[0054] An aseptic filling system, such as Figure 2 As shown, the sterile operating table 11 is a vertical flow sterile operating table, which includes a base, a purification chamber and a purification component arranged in sequence from bottom to top. Among them, a purification component is provided on the upper part of the purification chamber, and the purification component includes a primary filter 112, a first fan 113, and a first high-efficiency filter 114 arranged in sequence from top to bottom. During operation, the outside air is pre-filtered by the primary filter 112 and then sent into the first high-efficiency filter 114 by the first fan 113. The filling machine 12 is set on the work surface in the purification chamber. The purification chamber is close to the sterile transfer chamber 2 and can be connected to the sterile transfer chamber 2. The purification chamber is also equipped with an ultraviolet lamp 111, an ozone generator 116 and a lighting lamp 117. An operating glove opening 115 is provided on the transparent wall on the front side of the purification chamber.

[0055] The filling machine 12 includes a material conveying pipe 121, a sterile temporary storage tank 122, a material filling pipe 123, a material inlet 124, and a filling control valve 125. The sterile temporary storage tank 122 is connected to the material conveying pipe 121 and the material filling pipe 123. The material conveying pipe 121 is connected to the material inlet 124. The material filling pipe 123 is provided with a filling port and a filling control valve 125.

[0056] Furthermore, in this embodiment, the aseptic temporary storage tank 122 is further connected to a temporary storage tank overflow pipe 126 , and the material filling pipe 123 is further connected to a sterilization return pipe 127 .

[0057] When using the system of this embodiment for aseptic filling, the opening and closing door 23 is opened manually or by a robotic arm through the operating glove port 115, and then the sterilized packaging material a on the bracket 21 is transferred to the aseptic operating table 11 of the aseptic filling room 1, the opening of the packaging material a is aligned with the filling port, and the filling control valve 125 is opened to allow the liquid in the sterile temporary storage tank 122 to be filled into the packaging material a.

[0058] The rest is the same as Example 1.

[0059] Example 3

[0060] An aseptic filling system, such as Figures 3-4 As shown, the sterile transfer chamber 2 includes a bracket 21 , an air inlet 22 , an opening and closing door 23 , a box 24 , a second fan 25 , a second high-efficiency filter 26 and an air outlet 27 .

[0061] Among them, the bracket 21 is arranged in the box body 24, the top of the box body 24 is provided with an air inlet 22, the bottom is provided with an air outlet 27, the front side of the box body 24 is provided with a front door, and the side close to the aseptic filling chamber 1 is provided with an opening and closing door 23. A second fan 25 and a second high-efficiency filter 26 are provided in sequence between the air inlet 22 and the bracket 21.

[0062] When using the system of this embodiment for aseptic filling, the front door is opened, and the packaging material a to be sterilized is placed on the bracket 21 of the sterile transfer chamber 2. The vaporized hydrogen peroxide output by the vaporized hydrogen peroxide generator 3 is filtered by the second high-efficiency filter 26 by the second fan 25 and then sent to the packaging material a on the bracket 21, where the packaging material a is sterilized using the vaporized hydrogen peroxide.

[0063] The rest is the same as Example 1.

[0064] Example 4

[0065] In an aseptic filling system, a housing 24 is in cyclic communication with a vaporized hydrogen peroxide generator 3 via an air inlet 22, an air outlet 27, and a delivery pipeline. Furthermore, in this embodiment, the air inlet 22 and the air outlet 27 are connected by a sterilizing gas circulation channel within the housing 24, enabling full recycling of the sterilizing gas.

[0066] The rest is the same as Example 3.

[0067] Example 5

[0068] An aseptic filling system, such as Figure 5 As shown, the vaporized hydrogen peroxide generator 3 includes a gas delivery pipeline 31, a hydrogen peroxide storage tank 32, an atomizing nozzle 33, a compressed air delivery pipeline 34, a peristaltic pump 35, a regeneration heater 36, an atomizing heater 37, a three-way valve 38, a compressed air flow regulating valve 39, a discharge valve 310, a variable frequency high-pressure fan 311 and a dehumidification cracking catalyst 312.

[0069] The variable-frequency high-pressure blower 311, regeneration heater 36, three-way valve 38, atomizing heater 37, and atomizing nozzle 33 are arranged sequentially along the gas delivery direction on the gas delivery pipeline 31. The three-way valve 38 is also connected to a gas delivery branch. The dehumidification and cracking catalyst 312 is located on the gas delivery branch, which is connected to the gas delivery pipeline 31 via a three-way discharge valve 310. The atomizing nozzle 33 is connected to the hydrogen peroxide storage tank 32 via a peristaltic pump 35. The atomizing nozzle 33 is also connected to the compressed air delivery pipeline 34, which is equipped with a compressed air flow control valve 39 to adjust the flow rate of compressed air C input from the compressed air delivery pipeline 34.

[0070] The vaporized hydrogen peroxide generator 3 of this embodiment can realize the switching between sterilization and degradation functions, as follows:

[0071] like Figure 6 As shown, when the vaporized hydrogen peroxide generator 3 of this embodiment is used for sterilization, clean air B enters the gas delivery pipeline 31, passes through the variable frequency high-pressure blower 311, the regeneration heater 36, the three-way valve 38, the atomizing heater 37, and the atomizing nozzle 33 in sequence, and comes into contact with the vaporized hydrogen peroxide sprayed from the atomizing nozzle 33, thereby obtaining air A loaded with vaporized hydrogen peroxide, which is then delivered to the sterile transfer chamber 2 through the air inlet 22 as sterilizing gas.

[0072] like Figure 7 As shown, when using the vaporized hydrogen peroxide generator 3 of this embodiment for degradation, air A carrying vaporized hydrogen peroxide enters the gas delivery pipeline 31, passes through the variable frequency high-pressure blower 311, the regeneration heater 36, and the three-way valve 38 in sequence, and then enters the gas delivery branch. After the hydrogen peroxide in the air is degraded by the dehumidification and cracking catalyst 312, clean air B is obtained, which is returned to the gas delivery pipeline 31 through the three-way discharge valve 310 and output.

[0073] The rest is the same as Example 1.

[0074] Example 6

[0075] An aseptic filling system comprises an aseptic filling chamber, an aseptic transfer window and a vaporized hydrogen peroxide generator.

[0076] Among them, the aseptic filling room has the following characteristics:

[0077] 1. It includes a vertical flow sterile operating table and an air purification system composed of a fan, primary and high efficiency filters, and an ion generator. During operation, the outside air is pre-filtered by the primary filter and then sent to the high efficiency filter by the fan, reaching a high degree of cleanliness (Class 100) in the operating area. Finally, it is sterilized by ultraviolet light and ion generator, creating an ultra-clean and sterile state in the local area.

[0078] 2. Laminar flow mode: vertical laminar flow;

[0079] 3. Average wind speed: ≥0.4m / s, speed can be adjusted;

[0080] 4. Equipped with high-efficiency filters, the cleanliness level can reach Class 100;

[0081] 5. Stainless steel 304 worktop.

[0082] Sterile transfer window has the following characteristics:

[0083] 1. The sterile transfer window adopts vaporized hydrogen peroxide dry sterilization, which can achieve a 6 log sterilization effect;

[0084] 2. Equipped with high-efficiency filters, the cleanliness of the sterilization chamber can reach Class 100;

[0085] 3. The window is made of 316L stainless steel, which has good corrosion resistance;

[0086] 4. It can sterilize plastic bottles, glass products and bottle caps, and can be used with aseptic filling room and vaporized hydrogen peroxide generator to achieve packaging material sterilization and aseptic transfer.

[0087] Vaporized hydrogen peroxide generator has the following features:

[0088] 1. A 35% hydrogen peroxide solution is completely vaporized by a vaporized hydrogen peroxide generator and transported through pipelines for biological decontamination in confined spaces. During the vaporization process, hydrogen peroxide generates free hydroxyl groups, which oxidize and destroy cell components (such as lipids, proteins, and DNA). Gaseous hydrogen peroxide has the ability to kill various microorganisms such as bacteria, fungi, and viruses at room temperature. It is suitable for sterilizing air and surfaces under dry, low-temperature (room temperature), normal pressure / vacuum / positive pressure conditions;

[0089] 2. Vaporization rate (1-7g / min);

[0090] 3. Ultra-small design, easy to move;

[0091] 4. Can be connected to external pipeline for circulation sterilization;

[0092] 5. Sterilization capacity reaches 6 log sterilization effect;

[0093] 6. Optional real-time online monitoring of vaporized hydrogen peroxide concentration;

[0094] 7. Built-in hydrogen peroxide degradation device.

[0095] The above description of the embodiments is intended to facilitate understanding and use of the invention by those skilled in the art. It will be apparent that those skilled in the art can readily make various modifications to these embodiments and apply the general principles described herein to other embodiments without requiring inventive effort. Therefore, the present invention is not limited to the above-described embodiments. Improvements and modifications made by those skilled in the art based on the disclosure of the present invention, without departing from the scope of the present invention, should be within the scope of protection of the present invention.

Claims

1. An aseptic filling system, characterized in that: It comprises an aseptic filling room (1), an aseptic transfer room (2) and a vaporized hydrogen peroxide generator (3); The aseptic filling room (1) comprises an aseptic operating table (11) and a filling machine (12) arranged on the aseptic operating table (11); The aseptic transfer chamber (2) comprises a bracket (21) for placing packaging materials to be sterilized, an air inlet (22) connected to a vaporized hydrogen peroxide generator (3), and an opening and closing door (23) capable of connecting the aseptic transfer chamber (2) with an aseptic filling chamber (1).

2. The aseptic filling system according to claim 1, characterized in that: The aseptic operating table (11) is a vertical flow aseptic operating table, comprising a base, a purification chamber and a purification component arranged in sequence from bottom to top; The upper part of the clean room is connected to the clean room assembly, the filling machine (12) is arranged on the work surface in the clean room, the side of the clean room can be connected to the aseptic transfer room (2), and the clean room is also provided with an ultraviolet lamp (111); The purification component comprises a primary filter (112), a first fan (113), and a first high-efficiency filter (114) which are arranged in sequence from top to bottom.

3. The aseptic filling system according to claim 2, characterized in that: An operating glove opening (115) is provided on the wall of the clean room; An ozone generator (116) is provided in the purification chamber.

4. The aseptic filling system according to claim 1, characterized in that: The filling machine (12) comprises a material conveying pipe (121), a sterile temporary storage tank (122) and a material filling pipe (123); The aseptic temporary storage tank (122) is connected to a material conveying pipe (121) and a material filling pipe (123); the material conveying pipe (121) is connected to a material inlet (124); and the material filling pipe (123) is provided with a filling port and a filling control valve (125).

5. The aseptic filling system according to claim 4, characterized in that: The aseptic temporary storage tank (122) is also connected to a temporary storage tank overflow pipe (126); The material filling pipe (123) is connected to a sterilization reflux pipe (127).

6. The aseptic filling system according to claim 1, characterized in that: The aseptic transfer room (2) comprises a box body (24), a bracket (21) is arranged inside the box body (24), an air inlet (22) is arranged at the top of the box body (24), and an opening and closing door (23) is arranged on one side of the box body (24) close to the aseptic filling room (1).

7. The aseptic filling system according to claim 6, characterized in that: The box body (23) is provided with a second fan (25) and a second high-efficiency filter (26) between the air inlet (22) and the bracket (21).

8. The aseptic filling system according to claim 6, characterized in that: The box (24) is also provided with an air outlet (27) which is arranged at the bottom of the box (24). The box (24) is cyclically connected to the vaporized hydrogen peroxide generator (3) via the air inlet (22), the air outlet (27) and the delivery pipeline.

9. The aseptic filling system according to claim 1, characterized in that: The vaporized hydrogen peroxide generator (3) comprises a gas delivery pipeline (31) and a hydrogen peroxide storage tank (32) connected to the gas delivery pipeline (31).

10. A sterile filling method, characterized in that: The method is carried out using the system according to any one of claims 1 to 9, comprising the following steps: S1: placing the packaging material to be sterilized on a bracket (21) in a sterile transfer room (2); S2: starting the vaporized hydrogen peroxide generator (3) and introducing vaporized hydrogen peroxide into the sterile transfer chamber (2) through the air inlet (22) to sterilize the packaging material; S3: The sterilized packaging material is transferred to the sterile operating table (11) of the sterile filling room (1) and filled by the filling machine (12).

Images