Container treatment plant and method for forming and filling containers

Abstract

The invention relates to a container treatment plant with a blow molding machine (1) for forming containers (2) from preforms and for providing a container stream (3), with a transfer and distribution arrangement (4) connected to the blow molding machine (1) for receiving the containers (2) from the blow molding machine (1) and for dividing the container stream (3) into at least a first transport line (6) and a second transport line (7), wherein the first transport line (6) has a first filling system (8a) and the second transport line (7) has a second filling system (8b). According to the invention, the first filling system (8a) and the second filling system (8b) each have at least one first filling star (9a, 9b) and an adjoining second filling star (10a, 10b). The invention further relates to a method for forming and filling containers (2).

Description

The invention relates to a container treatment plant having a blow molding machine for forming containers from preforms and for providing a container stream, having a transfer and distribution arrangement which adjoins the blow molding machine for accepting the containers from the blow molding machine and for dividing the container stream into at least a first transport strand and a second transport strand, wherein the first transport strand has a first filling plant and the second transport strand has a second filling plant.When filling liquid products and in particular in the beverage industry, it is expedient if a plurality of treatment steps directly follow one another in order to be able to provide containers filled as cost-effectively, efficiently and quickly as possible in a large quantity.Integrated container treatment systems are known for this purpose, wherein a substantially identical throughput is then necessary in the individual treatment steps. In this case, it is possible in principle for containers to be jammed, temporarily stored or else introduced and discharged. With a view to an efficient method management, however, the container treatment plant preferably has machines and components which are blocked with one another, wherein the containers are then transferred directly between the various machines and components, in particular in the form of preforms or bottles. In particular, a transfer can take place directly between carousels and stars, so that a uniform throughput is then obtained along the entire container treatment plant.Against this background, it must also be ensured that the machines connected to one another are designed for the same throughput, wherein quite different working steps are carried out, which are scalable to different extents in practice with regard to the throughput.Against this background, DE 10 2021 107 727 A1 and DE 10 2020 130 535 A1 describe container treatment systems of the generic type in which a container stream of bottles formed in a blow molding machine is divided into a first transport strand and a second transport strand for filling. A filling machine is then provided in each transport line, wherein half the throughput results in comparison to the blow molding machine. It should be noted that modern blow molding machines are suitable for a very high throughput, taking into account the specific properties of the blow molding process. Also taking into account the apparatus complexity of a blow molding machine, scaling is particularly expedient in order to achieve efficient production.The invention is based on the object of making possible a further increase in efficiency in a container treatment plant of the generic type.The invention and the object are achieved by a container treatment plant according to claim 1 and a method for forming and filling containers according to claim 11.According to the invention, it is provided that the first filling system and the second filling system each have at least one first filling star and a second filling star connected thereto.In this context, the invention is based on the finding that, despite the already performed division of the container stream into the first transport strand and the second transport strand, the filling process can still limit the throughput to be achieved. Since a first subset is filled with the first filling star and a second subset is filled with the second filling star, a distinct increase in the throughput is possible compared to a filling system with only one filling star, wherein different filling scenarios can also be advantageously combined with one another by the division to two filling stars in each transport line.When the first partial quantity is introduced at the first filling star, the containers are initially empty and are also not completely filled. Accordingly, a comparatively high filling speed can be selected because a certain spraying, foaming or the like within the container can be accepted with respect to the first partial amount. The first subset is also selected such that the containers are not yet completely filled, so that specific inaccuracies in the filling process are unimportant, particularly in the case of rapid filling. The exact filling of the containers up to a predefined filling quantity can then take place at the second filling star thereafter when the second partial quantity is filled.Accordingly, it is preferably provided that the first subset is larger than the second subset. For example, it can be provided that the second subset corresponds to at most 40%, in particular at most 10%, of a predefined (target) fill volume.Preferably, it is provided that in the first transport line and the second transport line, the first filling stars are configured for a time-controlled partial filling of the containers with the first subset. This then results in a particularly simple procedure in order to introduce the preferably larger first partial quantity into the containers.At the second filling star, the preferably smaller second partial quantity can then be filled in under fill level control or weight control. For this purpose, the second filling stars can have load cells for the containers received for determining the weight and / or filling height sensors for determining the filling height at a plurality of, in particular all, filling points.Especially if, according to the previously described embodiment, the second partial quantity is smaller and corresponds in particular to less than 40%, preferably less than 10%, of the predefined filling volume, the risk of splashing, foaming or other liquid escape is also significantly reduced at the second filling star, wherein it is of course also easier for predefined filling volumes to be achieved in particular in a fill level-controlled or weight-controlled manner.Within the scope of the invention, it can be provided that in the first transport line and the second transport line, the first filling star and the second filling star are connected to a common liquid or filling product feed. The first partial quantity and the second partial quantity are then formed by the same liquid, wherein the described division serves only for optimizing the filling process and for increasing the throughput.In order to avoid an excessive space requirement for the filling stars in the invention, it is provided according to a preferred embodiment of the invention that in the filling systems the first filling star and the second filling star each have a plurality of filling elements and are directly adjacent to each other in a transfer area. Within the scope of such a preferred embodiment, the intermediate connection of a transfer star or another transfer device between the first filling star and the second filling star is then dispensed with, which would increase the space requirement.In the case of such a direct transfer from the first filling star to the second filling star, a collision of the filling elements must be avoided. In principle, it is conceivable to arrange the filling elements one above the other or next to one another in such a way that they cannot collide with one another even when mounted fixedly and immovably on the respective filling star.According to a preferred embodiment of the invention, however, it is provided that at least one of the two filling stars has a collision avoidance device for avoiding a collision of the filling elements in the transfer area. The provision of such a collision avoidance device relates in particular to an active movement of the filling elements on at least one of the two filling stars, as a result of which a suitable avoidance movement is achieved. In this case, it can be provided, for example, that in at least one of the two filling stars, the filling elements are designed to be pivotable and / or radially displaceable.The container treatment plant can also be configured to close the containers after filling. For this purpose, according to a preferred embodiment of the invention, it is provided that a closing machine, in particular a screw sealer, for attaching closures to the containers is provided in the first transport line and the second transport line downstream of the respective filling system.The closing machine can have a closing carousel with a plurality of closing stations, wherein the closing machine can connect to the respectively assigned filling installation via a transfer star.However, a configuration is preferred in which the closing carousel directly adjoins the respectively assigned second filling star in order to limit the necessary space requirement also with regard to the integration of the closing machine. Also during the transfer from the second filling star to the respectively adjoining closing carousel, a collision is naturally to be avoided with suitable measures and, if applicable, also with an active avoidance movement.Alternatively or preferably in addition to the closing of the containers, a labeling of the containers can also be provided.Against this background, according to a preferred embodiment of the invention, it is provided that at least one labeling machine for labeling the containers is arranged downstream of the filling systems. It is possible to provide a separate labeling machine for each transport line.Alternatively, all containers from both transport lines can be labeled with only one labeling machine. For example, the two transport strands can be brought together again before the labeling, in order to then direct the brought container stream into the labeling machine.An alternative embodiment that is independently protectable to this relates to a labeling machine for labeling the containers with a carousel having container receptacles. The labeling machine has a first transport path and a second transport path different therefrom, wherein the first transport strand is guided via the first transport path and the second transport strand is guided via the second transport path.Such a labeling machine can be useful in principle when containers are supplied from at least two separate transport lines, regardless of how they are treated and in particular filled beforehand. In each transport path, the containers are then guided along a labeling unit for applying labels.In particular, it can be provided that the first transport path extends over a first circumferential section and the second transport path extends over a second circumferential section disjunct therefrom.In a further possible embodiment of the invention, a common labeling machine for the two filling systems is provided behind the blow molding machine, which labeling machine is arranged in front of the filling systems. By means of such a labeling machine, the containers can be labeled before they are filled.Independently of the optional provision of the closing machine and / or the labeling machine, a merging arrangement can be provided within the scope of the invention in order to lead the first transport strand and the second transport strand together. Thereafter, for example, grouping into containers, plating or the like can usually be carried out.The entire container treatment plant formed at least from the blow molding machine and the two filling plants is preferably blocked. This means that the successive machines and components are connected to one another exclusively by transport devices which are provided for direct transfer to one another at a constant throughput. The containers are therefore not buffered or temporarily stored. Preferably, the successive machines and components are connected to one another only by transport stars or are directly adjacent to one another. A blocked configuration of the container treatment system is also expedient in particular if it comprises further components such as, for example, the at least one labeling machine described above and / or the closing machines.The invention also relates to a method for forming and filling containers, in particular by means of the container treatment plant described above, wherein containers are formed from preforms by blow forming and are conveyed as a continuous container stream, wherein the container stream is subsequently divided into at least a first transport line and a second transport line, wherein in the first transport line the respectively conveyed containers are filled with a first filling plant and in the second transport line the respectively conveyed containers are filled with a second filling plant. The method is then characterized in that the first filling system and the second filling system each have at least one first filling star and a second filling star connected thereto, and in that a first partial quantity is filled in each case with the first filling star and a second partial quantity is filled in each case with the second filling star.With regard to the method according to the invention, reference is also made to the above explanations, in particular with regard to the division of the first fill quantity and the second fill quantity with respect to the predefined fill volume.In the method, it can be provided that the first partial quantity at the first filling star and / or the second partial quantity at the second filling star in the two filling systems are filled into the containers in a free jet. Filling in a free jet can be realized particularly easily.Within the scope of the invention, filling in the free jet is also possible in particular for the second subset if this is smaller than the first subset. Depending on the circumstances, it is indeed also possible to prevent over-foaming or splashing out, or to reduce it to a sufficient extent, despite filling in the free jet.In principle, it is also possible within the scope of the invention for the containers at the first filling stars to be filled with first filling elements which are located completely above the container mouths of the containers, wherein the containers at the second filling stars are filled with filling elements which dip into the respective container mouth with a front dipping section.As already explained above, it is preferably provided that the first filling quantity is filled in in a time-controlled manner and / or that the second partial quantity is filled in in a fill level-controlled or weight-controlled manner, wherein a combination of these two measures is particularly preferred. Within the scope of the variant described above, a fill level sensor can also be arranged in the case of a front immersion section.In the method according to the invention, for example, between 50,000 and 150,000 containers per hour can be conveyed with the continuous container stream. At least for filling, the container stream is then divided as described into the two transport strings, each with half the throughput.The containers are preferably plastic bottles, in particular PET bottles, within the scope of the invention. Especially in the case of PET bottles for single use, low material usage, high cycle rates and overall low production costs are of particular importance.The PET bottles formed in the blow molding machine are then filled with a beverage or optionally also different beverages in the filling systems.The apparatus according to the invention and the method according to the invention are provided in particular to further increase the throughput of the blow molding machine. In the integrated process, it is often only the filling of a single filling product in the two separate transport lines that is provided, wherein alternatively different products can be processed in the two transport lines.If further machines such as closing machines and / or labeling machines or a labeling machine with at least two separate transport paths are then provided in the two transport lines, different closures or different labels can be provided for the two transport lines.The present invention relates to an embodiment with at least two transport lines, wherein a filling system with at least two filling stars is provided in each transport line. It is understood that in this respect a further scaling is conceivable. In the described manner, it is also possible in principle for three or more transport strings to be present, each having a filling installation.With respect to the individual filling systems, the invention is not restricted to configurations with exactly two consecutive filling stars, even if such a configuration is sufficient for many application purposes. Basically, embodiments with three or more consecutive filling stars are also possible, which then each fill an assigned portion of the total quantity into the containers.A preferred embodiment of the invention is explained below with reference to an exemplary figure.The single FIGURE schematically shows a container treatment plant according to the invention.The container treatment plant shown in the figure comprises a blow molding machine 1 for forming containers 2 in the form of disposable PET bottles from preforms.A container stream 3 of the containers 2 is provided by the blow molding machine 1 and is continued to a transfer and distribution arrangement 4 which adjoins the blow molding machine 1 and which divides the container stream 3 into a first transport strand 6 and a second transport strand 7 by means of two transfer stars 5.The first transport line 6 has a first filling system 8 aand the second transport line 7 has a second filling system 8 b. The filling systems 8 a, 8 bcomprise in each case a first filling star 9 a, 9 band a second filling star 10 a, 10 bconnected thereto.It is provided here that a first partial quantity is filled into the containers 2 with the first filling star 9 a, 9 band a second filling quantity with the second filling star 10 a, 10 b.In particular, it is provided that first the first larger partial quantity is filled into each transport strand 6, 7 at the first filling stars 9 a, 9 b, wherein the filling can take place in a time-controlled manner. In the subsequent second filling stars 10 a, 10 b, only a smaller second partial quantity then has to be filled in order to achieve a predetermined filling volume. The second fill quantity can be, for example, less than 40% and optionally also less than 10% of the predefined fill quantity.It is expedient here if the second filling quantity is filled in under fill level control or weight control.According to the invention, two aspects are combined with one another in a particularly advantageous manner with regard to the filling process, which aspects make possible a particularly simple process procedure and a high throughput.On the one hand, the container stream 3 discharged from the blow molding machine 1 is divided into the two transport strands 6, 7, as a result of which the throughput is halved in the two transport strands 6, 7 in comparison with the blow molding machine 1. Furthermore, the filling process is divided into the two filling stars 9 a, 9 b, 10 a, 10 bconnecting to one another in each transport line 6, 7, as described.In the context of the invention, a container stream containing 50,000 to 150,000 containers per hour can be provided, for example, by the blow molding machine in a blocked plant and can subsequently also be processed with the filling plants 8 a, 8 bin the two transport lines 6, 7.In the two filling systems 8 a, 8 b, the second filling star 10 a, 10 bin each case connects directly to the first filling star 9 a, 9 bat a transfer region 11.The filling stars 9 a, 9 b, 10 a, 10 beach have a plurality of filling elements, wherein at least one of the two filling stars 9 a, 9 b, 10 a, 10 bin each transport line 6, 7 has a collision avoidance device for avoiding a collision of the filling elements in the transition area 11. For example, it is possible to guide the filling elements on at least one of the filling stars 9 a, 10 b, 10 a, 10 bby an active movement out of a collision area. For such a movement, it is possible, for example, to control the path or curve.In the exemplary embodiment shown, a closing machine 12 is also provided in each transport line 6, 7, which closes the containers 2 with screw closures. According to a conventional design, the closing machine 12 comprises a closing carousel with a plurality of closing stations, wherein in each transport line 6, 7 the closing carousel of the closing machine 6 directly adjoins the respectively assigned second filling star 10 a, 10 b.As between the filling stars 9 a, 9 b, 10 a, 10 bof each transport strand 6, 7, a separate transfer star is accordingly also dispensed with when transferring to the closing machine 12, so that the space requirement can still be limited despite the division into the two transport strands 6, 7.The container treatment plant, which is blocked overall, can also have at least one labeling machine 13, wherein in principle a separate labeling machine can be arranged in each transport line 6, 7.However, the single figure shows a preferred alternative embodiment for this purpose, in which a single, common labeling machine 13 with a carousel is arranged downstream of the filling systems 8 a, 8 band the optionally provided closing machines 12, wherein the first transport strand 6 is guided over a first circumferential section 14 aand the second transport strand 7 is guided over a second circumferential section 14 bof the carousel.In this context, the invention is based on the finding that the application of labels with the labeling machine can take place over a comparatively short path, so that the division of the labeling machine 13 with the first circumferential section 14 aand the second circumferential section 14 bis particularly well possible.Of course, the two transport strands 6, 7 can be brought together again downstream of the labeling machine 13.It can be seen from the single figure that the two transport trains 6, 7 are substantially identical. Accordingly, in both transport lines 6, 7, filling with the same liquid, in particular a beverage, can also be carried out, wherein then expediently the same closures and labels are also applied.In principle, however, it is also possible to fill different liquids in the two transport lines 6, 7, wherein different closures and / or different labels can then expediently also be applied. It can then be expedient, precisely within the scope of such a configuration, to no longer bring the two transport strands 6, 7 together even after labeling, but to handle them separately overall.After labeling, for example the formation of bundles and / or a palletization can be provided for the two transport strands 6, 7 or a subsequently recombined container stream 3.List of reference characters1 Blow molding machine 2 Container 3 Container stream 4 Transfer and distribution arrangement 5 Transfer star 6 First transport strand 7 Second transport strand 8 aFirst filling system 8 bSecond filling system 9 a, bFirst filling star 10 a, bSecond filling star 11 Transfer region 12 Closing machine 13 Labeling machine 14 aFirst circumferential section 14 bSecond circumferential sectionReferences included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedDE 10 2021 107 727 A1

[0005] DE 10 2020 130 535 A1

[0005]

Claims

Container treatment plant having a blow moulding machine (1) for forming containers (2) from preforms and for providing a container stream (3), having a transfer and distribution arrangement (4) which adjoins the blow moulding machine (1) for accepting the containers (2) from the blow moulding machine (1) and for dividing the container stream (3) into at least one first transport strand (6) and one second transport strand (7), wherein the first transport strand (6) has a first filling plant (8a) and the second transport strand (7) has a second filling plant (8b), characterized in that the first filling plant (8a) and the second filling plant (8b) each have at least one first filling star (9a, 9b) and a second filling star (10a, 10b) which adjoins the first filling plant.Container treatment plant according to claim 1, characterised in that in the filling plants (8a, 8b) the first filling star (9a, 9b) and the second filling star (10a, 10b) each have a plurality of filling elements and directly adjoin one another in a transfer region (11).Container treatment plant according to claim 2, characterised in that at least one of the two filling stars (9a, 9b, 10a, 10b) has a collision avoidance device for avoiding a collision of the filling elements in the transfer region (11).Container treatment plant according to one of the preceding claims, characterized in that in the first transport line (6) and the second transport line (7) the first filling stars (9a, 9b) are set up for a time-controlled partial filling of the containers (2).Container treatment plant according to one of the preceding claims, characterized in that in the first transport line (6) and the second transport line (7) the first filling star (9a, 9b) and the second filling star (10a, 10b) are each connected to a common liquid feed.Container treatment plant according to one of the preceding claims, characterized in that a closing machine (12), in particular a screw sealer, for attaching closures to the containers (2) is provided in the first transport line (6) and the second transport line (7) downstream of the respective filling plant (8s, 8b).Container treatment plant according to claim 6, characterised in that the closing machines (12) each have a closing carousel with a plurality of closing stations and that the closing carousel directly adjoins the respectively associated second filling star (10a, 10b).Container treatment installation according to one of the preceding claims, characterized in that at least one labeling machine (13) for labeling the containers (2) is arranged downstream of the filling installations (8a, 8b).Container treatment plant according to claim 8, characterised in that a single, common labelling machine (13) with a carousel is arranged downstream of the filling plants (8a, 8b), wherein the first transport strand (6) is guided over a first circumferential section (14a) and the second transport strand (7) is guided over a second circumferential section (14b) of the carousel.Container treatment plant according to one of the preceding claims, characterized in that a merging arrangement is provided in order to merge the first transport strand (6) and the second transport strand (7).Method for forming and filling containers (2), in particular by means of a container treatment plant according to one of the preceding claims, - wherein containers (2) are formed from preforms by blow forming and are conveyed as a continuous container stream (3), - wherein the container stream (3) is subsequently divided into at least a first transport strand (6) and a second transport strand (7), - wherein in the first transport strand (6) the respectively conveyed containers (2) are filled with a first filling plant (8a) and in the second transport strand (7) the respectively conveyed containers (2) are filled with a second filling plant (8b), characterized in that the first filling plant (8a) and the second filling plant (8b) each comprise at least a first filling star (9a, 9b) and an adjoining second filling star (10a, 10b), and that a first partial quantity is filled with the first filling star (9a, 9b) and a second partial quantity is filled with the second filling star (10a, 10b).Method according to claim 11, characterised in that the containers (2) are filled at the first filling stars (9a, 9b) with first filling elements which are located completely above the container mouths of the containers (2) and that the containers (2) are filled at the second filling stars (10a, 10b) with second filling elements which dip into the respective container mouth with a front dipping section.Method according to claim 11 or 12, characterised in that the first filling quantity is filled in time-controlled manner and / or that the second partial quantity is filled in level-controlled or weight-controlled manner.Method according to one of Claims 11 to 13, characterized in that between 50,000 and 150,000 containers (2) are conveyed per hour using the continuous container stream (3).Method according to one of Claims 11 to 14, characterized in that the containers (2) are formed in the form of plastic bottles, in particular PET bottles, and are filled with a beverage or different beverages in the filling installations (8a, 8b).Method according to one of Claims 11 to 15, characterized in that the containers (2) from the first transport strand (6) and from the second transport strand (7) are brought together after filling and are then handled together.Method according to one of Claims 11 to 16, characterized in that the containers (2) are closed and / or labelled after filling.Method according to one of Claims 11 to 17, characterized in that the containers (2) are filled with a different filling product in the first transport strand (6) than in the second transport strand (7).

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