Filling system for the aseptic filling of liquid products into bottles

Description

[0001] The invention relates to a filling system for the aseptic filling of liquid products, in particular beverages.

[0002] Liquid products, such as beverages, are increasingly being filled in filling systems in which the individual production units, treatment units, and inspection units are connected exclusively by transfer starwheels or similar transport devices with circulating transport pockets and / or holders. A machine combination that is interlocked in this way is commonly referred to as a machine block. Such a machine block is known, for example, from DE 20 2009 019 170.

[0003] In order to be able to process different containers and / or different products simultaneously, it is also known from DE 10 2016 110 016 and FR 4 070 970 to divide a container flow directly behind a blow-molding machine into two transport lines and feed these to two downstream filling machines. According to FR 4 070 970, the containers can be fed alternately to a first and second filling machine via a switching starwheel, optionally filling the containers with the same product at both filling machines. In DE 10 2016 110 016, the containers are transported in the transport lines to the respective filling machine by means of a conveyor belt.

[0004] In addition to making filling processes more flexible in general, there is also a growing demand for an increase in system output, i.e. the number of containers that can be filled per unit of time. The limitation here has proven to be not only the filling process, which cannot be shortened indefinitely for physical reasons, but also the immediate subsequent handling of the filled containers. It has been found that the filled product can spill over when the conveyor speed changes direction as the speed increases. In addition, the closing process becomes less reliable due to the system's high peripheral speeds. Feeding caps is also problematic during correspondingly fast closing processes. In addition, clamps, particularly neck clamps, which grip the container in the neck area below the support ring, can only withstand the centrifugal forces acting on the container up to a certain point in their passive design.During filling in the filling machine, centrifugal forces increase significantly because the product flowing into the container increases the container's weight. Experience has shown that, depending on the bottle contour, fill level, and filled product, a physical maximum is reached at machine outputs of approximately 48,000 bottles per hour.

[0005] If a mechanical jam of bottles occurs on the machine, the very high line speed will cause serious damage, the repair of which is very time-consuming and costly.

[0006] Aseptic filling, for which system capacities of 8,000 to 54,000 bottles per hour are typical, requires additional technical complexity. For this process, the bottles are handled neck-handled throughout during transport. At the higher capacity range, comparatively large filling machines are required. These are designed as so-called carousel fillers with a ring-shaped, integrated aseptic zone, which is comparatively complex and space-consuming. The aseptic zone must be hydraulically sealed, for example, by a liquid barrier during rotation. Similar requirements apply to the capping machines.

[0007] As explained above, at machine outputs exceeding 36,000 bottles per hour, technical problems with neck handling become increasingly prevalent, both in terms of mechanical wear and the required precision. It is then essential to additionally stabilize the bottles with guide fittings on the bottle body. The guide fittings must be adjusted for each format, which is not possible automatically and is therefore disadvantageous.

[0008] For machine capacities of up to 36,000 bottles per hour, so-called tabletop fillers can be used as an alternative to carousel fillers. These fillers transport the bottles during filling using a star wheel. Corresponding design principles are known, for example, from EP 0 758 624 A1, EP 1 851 147 B1, EP 1 254 071 B1, and DE 20 2007 017 932 U1. The advantage of the tabletop design is that it does not require an additional aseptic area within the filler assembly.

[0009] Depending on the system's performance, different filling setups can be used, but the cleanroom enclosure, cleaning process, and ventilation / air treatment must be adapted accordingly. This requires a high level of individual design effort for each individual filling system.

[0010] It would also be desirable to make the outlet of the closed containers more compact, since subsequent outlet belts have to have long, straight sections on the inlet side in order to sufficiently slow down the flow of bottles and, if necessary, to be able to reject faulty bottles.

[0011] There is therefore a need for filling systems and processes for filling liquid products that allow bottles to be aseptically produced and filled in a single machine block, mitigating or completely eliminating at least one of the above-mentioned problems. It is also desirable to enable the simplest and most flexible operation and control of the filling system and process.

[0012] The stated object is achieved with a filling system according to claim 1.

[0013] Accordingly, the filling system serves for the aseptic filling of liquid products, especially beverages, into bottles or similar containers. For this purpose, the filling system comprises a machine block in which the individual production units, treatment units, and / or inspection units are interconnected by means of star-shaped transport means, such as transfer star wheels, and at least one cleanroom enclosure surrounding the machine block.

[0014] The machine block comprises: a blow-mold machine for producing bottles and supplying them as a bottle stream; at least one first and second conveyor line, each with a filling machine for filling the bottles; and a distribution unit for dividing the bottle stream among the conveyor lines when fully loaded such that the bottles can be filled continuously at all rotating filling positions of the filling machines. At least one of the filling machines is designed as a tabletop filler with a central star column (star column filler).

[0015] Preferably, all filling machines in the filling system are designed as tabletop fillers.

[0016] By dividing the bottle flow among the conveyor lines, the equipment required for single-track bottle production upstream of the distribution unit can be minimized. At the same time, the transport speed in the conveyor lines can be reduced compared to a single-track bottle flow, allowing the filling processes to be carried out on comparatively small filling machines with correspondingly small space requirements, and preventing spillage of the filled product.

[0017] In addition, the feeding of caps for subsequent capping is possible more reliably, and the capping process itself is more stable. The discharge speed on the discharge conveyors can also be reduced compared to the overall transport speed of the single-track bottle flow. This facilitates the removal of improperly filled and / or sealed containers or general service purposes. Overall, this principle has a positive impact not only on ongoing production operations but also on the installation and commissioning of the machines.

[0018] A fully loaded transport system means that the bottles can be transported from the blow molding machine to the filling machines without skipping any transport or treatment positions. However, individual transport and treatment positions can be deliberately left free, particularly if there is a malfunction, for example, in one of the filling machines. Targeted skipping of transport and treatment positions is possible, for example, by diverting bottles from the single-track bottle stream or from the resulting partial stream of a transport line, or by, for example, only loading every second circulating blow molding position (blow mold) of the blow molding machine with a preform.

[0019] The tabletop fillers can be designed as a series for different performance ranges and combined modularly. Suitable performance levels for the individual tabletop filler models include 8,000, 12,000, 18,000, 24,000, and 36,000 bottles per hour.

[0020] Table top fillers are also called star column fillers.

[0021] A table top filler / star column filler according to the invention has at least one of the following design features: The tabletop filler comprises a tabletop formed by the base plate of the cleanroom enclosure surrounding the tabletop filler. The tabletop filler comprises a rotary drive arranged below the tabletop / below the base plate of the cleanroom enclosure surrounding the tabletop filler. The tabletop filler comprises a star column that is continuously driven by the rotary drive and extends through the base plate / tabletop. A filler carousel sits on the star column. The filler carousel comprises a clamp carrier with clamps for holding the bottles and, arranged above it, a filling valve carrier with filling valves and associated rotating supply units. The tabletop / base plate is further designed to accommodate star columns of the infeed star and discharge star included in the tabletop filler and / or the subsequent capping machine.

[0022] In comparison, so-called carousel fillers have larger diameters and do not easily fit into conventional cleanrooms with a rectangular floor plan. Therefore, part of the circumference of the carousel filler is usually enclosed and protrudes from the otherwise essentially cuboid-shaped cleanroom. An additional cleanroom wall is located inside the carousel filler, radially inside the filling valves and along the machine axis. This creates an aseptic annular space for the carousel filler to fill. Since the interior of the filler is not located in a cleanroom area due to this annular space, the carousel filler's drive is connected directly to its star column and not guided through a tabletop.

[0023] For capacities exceeding 36,000 bottles per hour, the filling system then comprises two parallel tabletop fillers. The media supply, particularly product supply, ventilation, and cleaning (CIP), can be centralized, i.e., shared by both filling machines.

[0024] This allows for a modular design of the filling system with a uniform filling machine layout and reduced transport speed from the bottle filling stage onward. The associated advantages include: Reduced mechanical stress on components. The neck-handling clamping system can meet required service lives of, for example, one year, even at maximum capacity. More reliable bottle transfers in neck-handling. Manufacturing tolerances are easier to maintain for lower relative speeds. The comparatively small machines enable production to be carried out in stock while shortening throughput times in production, thus enabling future-proof production concepts. Even at maximum capacity, product spillage during / after cornering can be reliably prevented. The number of manufactured assemblies can be increased, thus increasing cost efficiency and the degree of standardization both in production and in production operations. Shorter setup times, as the lower conveyor speeds reduce the precision requirements during installation, and faster commissioning.Lower vessel heights and simplified venting of the filling valves are achieved, as the product lines from the vessel to the filling valve can be designed significantly shorter. Pressure-bearing components such as filler vessels are smaller relative to their output, simplifying compliance with local pressure equipment lines. In designs with two tabletop fillers, these can be used as a supporting structure for the platform plate of the filling system. An additional platform substructure is then unnecessary. More reliable and gentler bottle discharge with a correspondingly lower relative speed of the bottles. Partial load operation is possible in the event of a filling machine failure (50% operation).

[0025] Preferably, the blow molding machine and the distribution unit are arranged in a first cleanroom enclosure, the first transport line including the filling machine in a second cleanroom enclosure, and the second transport line including the filling machine in a third cleanroom enclosure. This facilitates partial load operation even when the filling machine is shut down.

[0026] The filling system preferably includes an air treatment unit for the shared air supply to the first, second, and third cleanroom enclosures. This simplifies the ventilation technology. The entire air treatment system can be combined into a single functional unit, reducing the number of filter-fan units and / or eliminating the need to place them on the machine housing. All filters and fans are preferably integrated into the air treatment unit, which then also includes the associated piping, for example, centralized exhaust air piping. Furthermore, directed air flow without pressure cascades is facilitated.

[0027] Preferably, the filling system comprises a converging device located outside the second and third cleanroom enclosures for converging the transport lines onto a common outfeed conveyor for vertical transport of the filled and sealed bottles. The bottles can thus be converged onto a comparatively slow outfeed stream for subsequent labeling.

[0028] The converging device enables capacity increases by connecting the filling machines in parallel while filling the same product in both filling machines. Bottles filled in the same way can then exit as a uniform bottle stream. This minimizes the space required for the filling machines and the bottle outlet.

[0029] Alternatively, the blow molding machine, the conveyor lines including filling machines, and the distribution unit are housed in a single cleanroom enclosure. This reduces equipment requirements and allows for easier access and more flexible arrangement of the individual components.

[0030] Preferably, the filling system then further comprises a converging device arranged within the common cleanroom enclosure for converging the transport lines onto a common outfeed conveyor for the upright transport of the filled and sealed bottles. Only one cleanroom lock is then required for the bottles on the outgoing side.

[0031] The partial streams guided along the transport lines can generally also be discharged separately from one another, for example in order to feed different labelling machines.

[0032] The filling system preferably includes partial discharge conveyors downstream of the filling machines, each of which is height-adjustable at least on the inlet side, for the upright transport of the filled and sealed bottles. This allows for easy adjustment of the bottle outlet to the respective bottle height.

[0033] In the area of the upstream capping machine, automatically adjustable guide elements for the bottles can then be present, particularly in the form of interchangeable sets.

[0034] The outfeed conveyors and / or the merging device can be part of the machine block or can be designed as connected units with a fundamentally independent function.

[0035] Preferably, the dividing star wheel comprises clamps that can be actively opened by means of rotating actuating elements and associated stationary actuating elements. The actuating elements associated with the first transport line are then arranged on a first common actuating plane, and the actuating elements associated with the second transport line are arranged on a second common actuating plane above or below the first actuating plane. The actuating elements are then arranged such that they can be actuated independently of one another with respect to the actuating planes.

[0036] In other words, the stationary actuating element of the first actuating level interacts only with the rotating actuating elements of the first actuating level, and the stationary actuating element of the second actuating level interacts only with the rotating actuating elements of the second actuating level. This enables space-saving and easy-to-construct current distribution by selectively opening the clamps either at a first transfer point to the first transport line or at a second transfer point to the second transport line.

[0037] The rotating actuating elements are, for example, rotary latches that can rotate around vertical axes. The stationary actuating elements are designed, for example, as actuating cams that, upon collision with the rotary latches, rotate them around the vertical axes to actuate the clamps. This is basically familiar from transfer starwheels for actuation in a single actuation plane.

[0038] In principle, other types of dividing stars would also be conceivable, for example a switching star with a switchable control cam, a sliding star with radially movable clamps, a transfer star with a circumferential linear motor system for individual clamps or the like.

[0039] Preferably, the transport lines each comprise at least one pitch-delay star for reducing a first transport pitch during / immediately before the division of the bottle stream to a smaller second transport pitch when filling the bottles.

[0040] The division delay star is then preferably arranged directly after the dividing star, thus receiving the bottles from it and then changing the first transport division upon further rotation around itself and in particular establishing the second transport division.

[0041] In principle, a pitch delay star can be designed as a switching star with a switchable control cam, a sliding star with radially displaceable clamps, or a transfer star with a circumferentially extending linear motor system for individual clamps.

[0042] This enables a comparatively compact distribution of the bottle flow while simultaneously adjusting the transport pitch and achieving comparatively high transport speeds. The transport pitch is adjusted while maintaining the separation of the containers, i.e., maintaining their spacing from one another.

[0043] According to the invention, the filling system further comprises a central product distributor for supplying the filling machines with product to be filled from a common product supply, in particular a storage tank, and / or a central closure cap distributor for supplying the closing machines assigned to the filling machines with closure caps from a common closure cap supply, in particular a storage container.

[0044] The product distributor, for example, is a so-called valve hub through which the product is routed to the individual filling valves of the filling machines.

[0045] The cap distributor, for example, is a cascade-shaped arrangement of inlet channels that lead from the storage container to the capping machines.

[0046] Such distribution of product and / or caps reduces the space required for product and cap stocks and simplifies the provision and replenishment of the respective stocks.

[0047] Preferably, the filling system also includes a central cleaning unit for CIP cleaning of the filling machines or the machine block as a whole with central cleaning agent supply and return.

[0048] Preferably, the filling system further comprises a control device for the joint control of the filling machines and / or for the control synchronization of control units present on the filling machines. The control synchronization includes, for example, a type-specific parameter transfer, particularly regarding a product to be filled uniformly. This simplifies the control and operation of the filling machines.

[0049] For example, variety parameters can be transferred from one filling machine to another, requiring only one (common) input or similar operating step. The filling machines can nevertheless each include a separate control unit and / or display unit. An input made there can then be duplicated / mirrored and applied to the other filling machine.

[0050] Such a shared control system allows the filling machines to be represented and / or addressed as a single processing unit (filling machine) in the operating concept of the machine block. The control-technical assignment of the blow molding positions (blow molds) of the blow molding machine and the filling positions (filling devices) of the filling machines is possible by assigning corresponding shift registers to the respective control devices.

[0051] The common control device and / or the individual control units of the filling machines can, for example, be arranged in a common control cabinet.

[0052] The shared control of the filling machine enables a clear assignment of the blow molding positions and filling positions used for each bottle, enabling traceability of the filled bottles throughout the filling plant's value chain. At least one downstream labeling machine and its associated labeling positions can also be assigned.

[0053] Preferably, the filling system, in particular the shared control device, comprises a central base unit for controlling the inspection technology for the outlets of both transport lines. Such a control system can have the following functions, known in principle: Full container control for filling machines and closing machines, for example, comprising: fill level control (using high-frequency, infrared, camera, gamma, or X-ray technology); closure and retaining ring detection (using sensor and camera technology); filling machine management; production management; quality management; safety management; and / or adjustment of guide rails and / or inspection height.

[0054] Preferably, the filling system further comprises a heating module upstream of the blow molding machine for heating preforms and a disinfection unit arranged between the heating module and the blow molding machine for disinfecting the preforms.

[0055] The heating module preferably comprises a locking starwheel on the input side for the controlled release and blocking of the preform feed. The locking starwheel is rotationally driven by a stepper motor. The stepper motor enables precise release and feed on the one hand, and blocking and retention of individual preforms on the other, for example, if no or only every other blow molding position of the blow molding machine is to be fed.

[0056] Thanks to the precise control and movement of the stepper motor, compared to conventional pneumatic locking units, for example, the control signals for the stepper motor can be entered directly into the respective machine shift register, thus enabling control of the preform feed without the need for additional sensors to monitor the presence of preforms or bottles. Furthermore, the effort required to set up and inspect corresponding sensors, which previously had to be precisely adjusted and frequently checked due to the relatively high transport speeds, is eliminated.

[0057] The described process is used for the aseptic filling of liquid products, especially beverages, into bottles or the same containers.

[0058] The bottles are produced in a blow-mold machine, divided into at least a first and second sub-stream, and each sub-stream is filled in a separately assigned filling machine. From production to filling, the bottles are transported and handled under aseptic conditions in a single machine block. Furthermore, filling takes place in at least one of the transport lines in a tabletop filler with a central star column. This allows the advantages described in claim 1 to be achieved.

[0059] After being filled uniformly in the filling machines, i.e. with the same product, the bottles can be re-merged into a common outgoing bottle stream.

[0060] If the filling machines are filled differently with regard to the product, the bottles can also be discharged as separate bottle streams.

[0061] Preferably, a first transport pitch in the transport lines created by the splitting of the single-track bottle stream is reduced to a second transport pitch for filling the bottles by means of a pitch delay. This means that the transport pitch of the partial streams is reduced before filling by means of a pitch delay during the circulating transport of the bottles.

[0062] Preferably, the partial streams continue to be transported under aseptic conditions after the bottles have been filled, at least until they are combined into a common outlet stream. In another advantageous embodiment, the partial streams are discharged separately from the aseptic handling area after the bottles have been filled and then combined into a common outlet stream.

[0063] The combined outflow stream can advantageously be fed as a whole to one labelling machine, while separately discharged partial streams can each be fed to individually assigned labelling machines.

[0064] Preferably, the filling machines are jointly controlled by the operator by entering uniform variety parameters and applying them in the filling machines by means of automatic transfer of the variety parameters from a common control device, in particular from one filling machine to another.

[0065] Preferred embodiments are illustrated in the drawings. They show: Fig. 1 shows a schematic plan view of the filling system in a first embodiment; Fig. 2 shows a schematic plan view of a distribution device; Fig. 3 shows a partial side view of a distribution star; Fig. 4 shows a schematic plan view of the filling system in a second embodiment; Fig. 5 shows a schematic plan view of the filling system in a third embodiment; and Fig. 6 shows a schematic plan view of the inlet area of a heating module of the filling system.

[0066] As the Fig. 1 As can be seen, the aseptically operating filling system 1 in a first advantageous embodiment comprises a machine block 2 and at least one clean room enclosure 3 surrounding it. The machine block 2 comprises a blow molding machine 4, two filling machines 5, 6 and a distribution device 7 for dividing a single-track bottle stream 8 into a first partial stream 9 along a first transport line 9a with the first filling machine 5 and into a second partial stream 10 along a second transport line 10a with the second filling machine 6.

[0067] The single-track bottle flow 8 consists of bottles 8a produced in the blow molding machine 4 at continuously rotating blow molding positions 4a (only one of which is shown in each case). The distribution device 7 comprises continuously rotating transport positions 7a, see also the Fig. 2 .

[0068] Machine block 2 is characterized by the fact that both the single-track bottle stream 8 and the resulting substreams 9, 10 are transported individually, i.e., at a fixed distance from one another, by star-shaped transport means 11, such as transfer stars. This results in an interlocking design of the blow-molding machine 4, the filling machines 5, 6, and the distribution device 7.

[0069] At least one of the filling machines 5, 6, preferably both, is designed as a tabletop filler with filling positions 5a, 6a rotating on a transport star (only one of each is shown). This means that, in contrast to a carousel filler with a container carousel, the bottles in the tabletop filler are handled, in particular, by neck handling on a star that is continuously rotatably mounted on a tabletop by means of a star column. In contrast to the carousel filler, the tabletop filler does not include an internally isolated aseptic area around the filling positions 5a, 6a with their filling elements, for example, by a liquid barrier, but can be freely arranged within the respective cleanroom environment.

[0070] The distribution device 7 comprises a distribution star 12 and preferably directly adjoining division delay stars 13, 14.

[0071] As the Fig. 2 In this regard, the dividing star 12 preferably comprises a plurality of first clamps 15 which are evenly distributed around the circumference and which transfer every second bottle 8a of the single-track bottle stream 8, for example bottles with an odd ordinal number, to the first transport line 9a to form the first partial stream 9, and second clamps 16 which transfer the bottles 8a arranged in between in the bottle stream 8, for example those with an even ordinal number, to the second transport line 10a to form the second partial stream 10. The entirety of the clamps 15, 16 corresponds to the transport positions 7a of the distribution device 7 for the bottles 8a. The dividing delay stars 13, 14 comprise clamps 13a, 14a corresponding to every second transport position 7a.

[0072] As the Fig. 2 As can also be seen in this regard, the division delay star wheels 13, 14 have a first transport pitch 13b, 14b during the transfer of the bottles 8a. This corresponds to twice the transport pitch of the dividing star wheel 12 in the sense that the clamps 13a of the first division delay star wheel 13 are assigned to the first clamps 15 of the dividing star wheel 12, and the clamps 14a of the second division delay star wheel 14 are assigned to the second clamps 16 of the dividing star wheel 12 (or vice versa).

[0073] The pitch delay stars 13, 14 are designed to reduce the transport pitch of the first and second partial streams 9, 10 compared to the first transport pitch 13b, 14b to a second transport pitch (not shown), which preferably corresponds to the transport pitch (not shown) of the filling positions 5a, 6a of the filling machines 5, 6.

[0074] The first clamps 15 of the dividing star 12 are opened in a controlled manner, preferably as described below, at a first transfer point 17 with the first division delay star 13, the second clamps 16 of the dividing star 12 are opened accordingly at a second transfer point 18 with the second division delay star 14 and the bottles 8a are transferred to the transport lines 9a, 10a.

[0075] Also schematically indicated are an optional first discharge device 19 for the first partial flow 9 and an optional second discharge device 20 for the second partial flow 10 for the selective discharge of bottles 8a from the transport line 9a, 10a in the event of an operational malfunction of the respectively assigned filler 5, 6. It would also be conceivable to arrange a discharge device between the blow molding machine 4 and the distribution device 7 (not shown).

[0076] The Fig. 3 shows a preferred actuating mechanism for the first and second clamps 15, 16. Accordingly, the dividing star 12 comprises a first rotating actuating element 21 assigned to each first clamp 15 and a rotating second actuating element 22 assigned to each second clamp 16. The actuating elements 21, 22 are preferably designed as rotary locks rotatable about vertical axes 21a, 22a, the rotation of which (depending on the direction of rotation) opens (or closes) the respectively assigned clamp 15, 16.

[0077] The rotary latches (circumferential actuating elements 21) assigned to the first clamps 15 are arranged in a first common actuating plane 23, and the rotary latches (circumferential actuating elements 22) assigned to the second clamps 16 are arranged in a second actuating plane 24 which is offset upwards (or downwards) in a control-technically decoupling manner.

[0078] This means that the distance 25 between the actuating levels 23, 24 is so large that at least one stationary (non-rotating) actuating element 26 arranged in the first actuating level 23, which is designed, for example, as a control cam, only actuates the rotary locks of the first actuating level 23 and thus the first clamps 15 and at least one stationary actuating element 27 arranged in the second actuating level 24 (for example, a Fig. 2 concealed control cam) only the rotary latches 22 of the second actuation level 23 and thus the second clamps 16 are actuated.

[0079] The stationary actuating elements 26, 27 (control cams) for opening the clamps 15, 16 are arranged on the dividing star 12 in the area of the transfer points 17, 18.

[0080] Such an actuating mechanism with rotating actuating elements 21, 22 and stationary actuating elements 26, 27 enables a relatively simple construction and a space-saving division of the bottle flow 8. This ensures reliable switching of the clamps 15, 16 in the area of the respective transfer point 17, 18 at a high transport speed.

[0081] In the Fig. 1 Closing machines 29, 30, which are each connected to the filling machines 5, 6, for closing the bottles 8a in the respective partial flow 9, 10 can be seen, as well as partial outlet conveyors 31, 32 which are connected downstream of these by means of transfer stars 11 and which essentially form the outlet-side end of the transport lines 9a, 10a.

[0082] The partial discharge conveyors 31, 32 are designed, for example, as conveyor belts for upright bottle transport and are preferably height-adjustable, at least on the inlet side. This facilitates easy format adjustment during bottle transfer from the neck handling.

[0083] The transport lines 9a, 10a or the partial outlet conveyors 31, 32 optionally combine at a (also only schematically indicated) merging device 33, such as a switch or similar transport-technical merger, to form a common outlet stream 8' of the bottles 8a, for example on a common outlet conveyor 34, which, for example, also comprises at least one conveyor belt for upright bottle transport.

[0084] The outlet stream 8' normally consists of the bottles 8a of the originally single-track bottle stream 8, but is multi-track and accordingly slower.

[0085] In the area of the common discharge conveyor 34, for example, a rejection table (not shown) can be arranged, which serves, for example, for the service rejection of bottles 8a from the discharge stream 8'. In principle, separate rejection tables could also be provided at each of the partial discharge conveyors 31, 32. A collecting container (not shown) for rejected bottles 8a is then provided at each rejection table. An inspection unit (not shown) can be assigned to the respective rejection table.

[0086] The filled bottles 8 leave the area enclosed by the cleanroom enclosure 3 on the discharge conveyor 34 through a (schematically indicated) cleanroom lock 35, which is thus assigned to both filling machines 5, 6. As the Fig. 4 In this regard, however, a clean room lock 35, 36 can also be assigned separately to the filling machines 5, 6.

[0087] The merging device 33 and the common outlet conveyor 34 are then omitted, so that the partial streams 9, 10 can be discharged separately and processed downstream, for example, in two independent labeling machines (not shown). In contrast, the discharged common outlet stream 8' is preferably fed to a single labeling machine (not shown).

[0088] As the Fig. 1 As can be seen, the filling system 1 further comprises a heating module 37 for preforms 8b, which is assigned to the input side of the blow molding machine 4, and a disinfection unit 38 arranged between the heating module 37 and the blow molding machine 4 for disinfecting the preforms 8b, for example by means of an electron beam or H 2 O 2 . The disinfection unit 38 is only indicated schematically and can be arranged in a manner known in principle in the region of a transfer star 11.

[0089] The enclosure surrounding the disinfection unit 38 (schematically indicated) can be connected to the clean room 3, 3a surrounding the blow molding machine 4 on the ventilation side. A separate ventilation / extraction system is also conceivable, for example, to remove vapors generated during disinfection.

[0090] During regular production operation of filling line 1, the preforms 8b and the bottles 8a are transported and processed at full capacity. This means that all circulating blow molding positions 4a are loaded with one preform 8b each, as well as all transport positions 7a of the distribution device 7 and all filling positions 5a, 6a are loaded with one bottle 8a each.

[0091] Although the filling plant 1 is designed for full transport, other operating modes are also conceivable, for example in the event of an operational malfunction or changeover in one of the fillers 5, 6. In this case, temporarily only every second blowing position 4a of the blowing machine 4 can be equipped with a preform 8b, so that the bottles 8a blown from it are only guided at every second transport position 7a through the distribution device 7 to the respectively further operated transport line 9a, 10a.

[0092] The distribution device 7 could alternatively comprise a dividing starwheel 12 in the form of a sliding starwheel, a pitch-shifting starwheel, or the like. In this case, the pitch diameter and / or the transport pitch of the dividing starwheel 12 would change as the bottles 8a circulate, in order to divide the bottle stream 8 into the first and second partial streams 9, 10 and, for example, to prevent a collision of clamps 15, 16 of the distribution starwheel 12 with unassigned clamps 13a, 14a of the subsequent pitch-shifting starwheels 13, 14 or transfer starwheels 11 and / or to already introduce a pitch shift at the dividing starwheel 12.

[0093] For this purpose, the clamps 15, 16 of the dividing star 12 could be pivoted, shifted and / or moved circumferentially, i.e. in or against their direction of rotation, relative to the dividing star 12 in a suitable manner in order to transfer the bottles 8a at the transfer points 17, 18 and thereby avoid collisions between assemblies that are not assigned to one another (which transfer bottles 8a at the respective other transfer point 17, 18).

[0094] For the sake of clarity, the Fig. 1 Some system components that are mandatory for aseptic filling are omitted, such as product supply, clean room ventilation and machine control. In this regard, reference is made to the Fig. 4 bis 6 It is understood that features described and / or illustrated only once may be present in all embodiments of the filling system 1.

[0095] The Fig. 4 and 5show alternative configurations of filling system 1. Corresponding reference symbols are used for individual components and product streams, so that associated structures and functions are not explained again. Where reference symbols are omitted, these are also apparent from the illustrated context.

[0096] According to Fig. 4 A product distributor 41 is provided for the joint product supply of the filling machines 5, 6. The product distributor is connected on the inlet side to a product tank 42 with a shared product supply 43 and on the outlet side to the filling machines 5, 6 via supply lines 44, 45. In these, the liquid product is distributed in a manner known in principle to the individual filling devices at the filling positions 5a, 6a. The product distributor 41 can thus be considered a central valve hub for the filling devices. The product supply 43 could also be supplied from other central containers or lines via the central product distributor 41 / valve hub.

[0097] Furthermore, the filling system 1 comprises a central air treatment unit 46, which is connected to the cleanroom enclosure 3 via ventilation ducts 47 to create a cleanroom atmosphere suitable for aseptic filling. Individual methods and devices for such air treatment are known and therefore not explained in detail.

[0098] Shown in the Fig. 4 the closing machines 29, 30 assigned to the filling machines 5, 6 and a closure cap distributor 51, which is connected on the input side to a storage container 52 with a closure cap supply 53 and on the output side by means of feed chutes 54, 55 to the closing machines 29, 30.

[0099] The closure cap distributor 51 can, for example, be integrated into a cascade-like arrangement of feed chutes 54, 55, which are then designed with a suitable gradient for transporting the closure caps to the closing machines 29, 30. The closure caps can also be particularly efficiently disinfected in the area from the storage container 52 to the closure cap distributor 51 in a manner known in principle.

[0100] With the product distributor 41 and / or the closure cap distributor 51 for the filling machines 5, 6, the equipment expenditure and the operating expenditure for the continuous provision of the product supply 43 and the closure cap supply 53 can be reduced compared to separate storage for the individual filling machines 5, 6.

[0101] The Fig. 5 shows a variant of the filling plant 1 as an example based on the Fig. 4 illustrated embodiment, according to which separate clean room enclosures 3a, 3b, 3c are provided for the blow molding machine 4 and the distribution unit 7 on the one hand and each of the filling machines 5, 6 on the other hand, which together form the clean room enclosure 3 of the machine block 2.

[0102] The central air treatment unit 46 is then connected via first ventilation ducts 47 to a first clean room enclosure 3a around the blow molding machine 4 and distribution unit 7, via second ventilation ducts 48 to a second clean room enclosure 3b around the first filling machine 5, and via third ventilation ducts 49 to a third clean room enclosure 3c around the second filling machine 6.

[0103] This results in the filled bottles 8 being discharged from the respective cleanroom enclosures 3b, 3c as partial product streams 9, 10 through separate cleanroom locks 35, 36. Downstream, the partial product streams 9, 10 can be combined or processed separately (not shown), for example, they can be labeled together or separately.

[0104] The separate clean room enclosures 3a, 3b, 3c enable unhindered production operation at partial capacity of the filling plant 1 when one of the filling machines 5, 6 is out of operation for maintenance purposes.

[0105] The central air treatment unit 46 then enables flexible and economical air treatment in the clean room enclosures 3a, 3b, 3c used for production.

[0106] This also applies similarly to the described central product distribution to the filling machines 5, 6, which is also possible without restriction with separate clean room enclosures 3a, 3b, 3c.

[0107] Preferably, the filling system 1 comprises a central CIP unit for cleaning the filling machines 5, 6 and other aseptic system areas of the machine block 2. The CIP unit can operate according to the principles proven for aseptic production areas and is therefore neither shown nor described in detail.

[0108] The Fig. 5 1 shows, representative of the other described embodiments, a variant of the filling system 1, according to which the filling machines 5, 6 can be combined in terms of conveying technology to form a jointly operated product unit. Shown schematically by way of example are a common control device 61 with an input and output unit 62, for example a touchscreen or the like, and control units 65, 66 present on the blow-molding machines 5, 6 or assigned to them elsewhere. The control units 65, 66 can, for example, also control the closing machines 29, 30 assigned to the filling machines 5, 6 in a manner known in principle.

[0109] The common control device 61 and its subordinate control units 65, 66 form a control module 67, which is integrated and can be operated as a single production unit in a higher-level control system 68 of the filling plant 1.

[0110] Thus, the filling machines 5, 6, particularly for filling one and the same product, can be controlled like a single machine and easily operated using a single input and output device 62. This not only simplifies the operation of the filling machines 5, 6, but also enables joint storage of variety parameters in the common control device 61 and easy transfer of such variety parameters to the filling machines 5, 6. This means that operating errors due to possibly different inputs for the filling machines 5, 6 can be avoided, and the assignment of the variety parameters for the filling machines 5, 6 can be automated.

[0111] In principle, it would also be conceivable to implement the common control device 61 in one of the control units 65, 66 and / or to automatically assign the common control device 61 to the control device 65, 66 at which an input is to be made.

[0112] Variety parameters can be transferred automatically between the control units 65, 66 of the filling machines 5, 6. Which of the above-mentioned operator concepts is advantageous in each case depends, for example, on the spatial arrangement of the filling machines 5, 6 in machine block 2 and / or on the equipment of the individual filling machines 5, 6 with input and output units 62.

[0113] The Fig. 6 shows a preferred variant of the heating module 37, in which a locking star 91 is present on the input side, which is driven by a stepper motor 92 (in Fig. 6(hidden). The locking star 91 serves for the mechanically controlled release and blocking of the feed of the preforms 8b into the heating module 37. Likewise, the feed of the preforms 8b can be timed by means of the stepper motor 92 such that only every second rotating heating position 37a (only one of which is shown) of the heating device 37 is loaded with a preform 8b and, subsequently, only every second rotating blow molding position 4a of the blow molding machine 4.

[0114] The locking star 91 is then preferably arranged upstream of a sawtooth star 93, with which the transport division of the preforms 8b is produced to match the rotating heating positions 37a.

[0115] The stepper motor 92 enables a precisely controlled and easy-to-use feed of the preforms 8b. Firstly, the feed is possible at a higher speed and with greater precision than with known pneumatic locking devices. Secondly, the precise and reliably controlled feed of the preforms 8b by means of the stepper motor 92 eliminates the need to check the individual rotating heating positions 37a to determine whether or not they are occupied by a preform 8b. This means that the stepper motor 92 enables such precise and reliable feed of the preforms 8b that additional sensors for the above-mentioned monitoring of the heating positions 37a and the associated effort, both in terms of equipment and in setting up the heating module 37, are unnecessary.

[0116] The filling system 1 can be operated, for example, as follows: In normal production operation, type parameters are preferably entered into the common control device 61 for filling a specific product in both filling machines 5, 6 and transferred from there to the control units 65, 66 of the filling machines 5, 6 and applied there for the subsequent production operation when the transport is fully staffed.

[0117] The variety parameters can be transferred between the filling machines 5, 6 in such a way that only one common input is necessary.

[0118] For this purpose, the common control device 61 and / or the separate control units 65, 66 of the filling machines 5, 6 can be used, if necessary with a common representation or separate representation with respect to the control system 68 of the filling plant 1 as a whole.

[0119] A shift register can be distributed among the filling machines 5, 6 duplicated in this way and the production data of the bottles 8a can be assigned to the filling machine 5, 6 used in each case.

[0120] Along the production chain in the filling plant 1, a clear assignment of blow molds and filling devices is possible in the sense of traceability of the bottles 8a.

[0121] The preforms 8b are continuously fed to all heating positions 37a of the heating module 37 and the single-track bottle stream 8 is produced by blowing the bottles 8a at all blowing positions 4a in the blow molding machine 4.

[0122] The bottle stream 8 is continuously fed to the distribution device 7. This distributes the bottles 8a from every second transport position 7a alternately to the first and second transport lines 9a, 10a.

[0123] The bottles 8a could also be distributed on a switching starwheel by activating a control cam such that, in the event of a malfunction or prolonged production interruption on a transport line 9a, 10a, all bottles 8a of the bottle stream 8 are diverted to the respective undisturbed transport line 9a, 10a. The blow molding machine 4 could then operate at half speed even when the blow molding positions 4a are fully occupied.

[0124] When the transport is fully loaded, the initial transport pitch 13b, 14b in the transport lines 9a, 10a is reduced to the transport pitch of the filling machines 5, 6.

[0125] This allows the rotational speeds and transport speeds of subsequent units to be reduced to minimize the problem of spillage of the filled product. Furthermore, the maximum required machine output of 36,000 bottles per hour each in transport lines 9a and 10a, i.e., after splitting the original bottle flow 8, can also be handled by the tabletop fillers, which are generally advantageous in aseptic production.

[0126] The partial streams 9, 10 are filled in the filling machines 5, 6 at all filling positions 5a, 6a and closed in the subsequent closing machines 29, 30.

[0127] The filled partial streams 9, 10 are discharged either after merging or separately from the respective clean room enclosure 3, 3b, 3c and can be labelled either as a common outlet stream 8' or as separate partial streams 9, 10 downstream in a manner known in principle.

[0128] In the event of a malfunction / defect in a filling machine 5, 6, it is possible to selectively insert every second preform 8b into the heating module 37, so that the still properly functioning filling machine 5, 6 can continue filling. It would also be conceivable to temporarily discharge every second preform 8b after the fully occupied heating module 37.

[0129] If a filling machine 5, 6 and / or a capping machine 29, 30 malfunctions, the locking star wheel 91 at the inlet of the heating module 37 can be stopped / locked. The bottles 8a and preforms 8b assigned to this filling machine 5, 6 can then be ejected while the other filling machine 5, 6 continues production.

[0130] Bottles 8a assigned to a malfunctioning filling machine 5, 6 are to be ejected, preferably after the dividing starwheel 12. To prevent collisions between this and the subsequent dividing delay starwheels 13, 14, these preferably rotate continuously. The bottles 8a can then be ejected at a dividing delay starwheel 13, 14 or at a transfer starwheel 11, if additionally present.

[0131] The filling system 1 and the aseptic filling process were described based on a preferred division of a single, single-track bottle stream 8 into two partial streams 9, 10 or transport lines 9a, 10a. In principle, however, a division of several bottle streams 8 and / or into a larger number of partial streams 9, 10 or transport lines 9a, 10a would also be conceivable, for example by connecting dividing starwheels 12 in parallel or in series with dividing delay starwheels 13, 14 or the like that decrease in size according to the number of bottles 8a.

[0132] The bottle stream 8 consists of plastic bottles 8a, in particular PET, produced in the blow-molding machine 4. However, a corresponding division of other or additional bottles 8a from at least one single-track bottle stream 8 into substreams 9, 10 in the manner described above is also conceivable.

[0133] The basic principle for this is always the division of the bottle flow 8 when the transport is fully loaded immediately before filling the bottles 8a in order to solve the described task for the improved filling / closing of the bottles 8a under aseptic conditions.

[0134] Furthermore, the design of the tabletop filler enables a particularly flexible and modular filling system for aseptically filled products to be constructed with little effort.

[0135] It is particularly advantageous to design all filling machines 5, 6 of the filling system 1 as tabletop fillers.

Claims

1. Filling system (1) for the aseptic filling of liquid products, comprising: - a machine block (2) with a blow molding machine (4) for producing bottles and supplying them as a bottle stream (8), with at least a first and second transport line (9a, 10a) each comprising a filling machine (5, 6) for filling the bottles, and with a distribution unit (7) for distributing the bottle stream to the transport lines when transport is fully occupied, such that the bottles can be filled continuously at all circulating filling positions (5a, 6a) of the filling machines; - at least one clean room enclosure (3) surrounding the machine block; and - a central product distributor (41) for supplying the filling machines (5, 6) with product to be filled from a common product supply (43) and / or a central closure cap distributor (51) for supplying closure caps from a common supply container (52) to closure machines (29, 30) assigned to the filling machines, wherein at least one of the filling machines is designed as a tabletop filler with a central star column.

2. Filling system according to claim 1, wherein the blow molding machine (4) and the distribution unit (7) are located in a first clean room enclosure (3a), the first transport line (9a) including the filling machine (5) is arranged in a second clean room enclosure (3b) and the second transport line (9b) including the filling machine (6) is arranged in a third clean room enclosure (3c).

3. Filling system according to claim 2, further comprising an air treatment unit for supplying air to the first, second and third clean room enclosures (3a, 3b, 3c).

4. Filling system according to claim 2 or 3, further comprising a combining device (33) arranged outside the second and third clean room enclosures (3b, 3c) for combining the transport lines (9a, 10a) onto a common discharge conveyor (34) for transporting the filled and sealed bottles (8a) in an upright position.

5. Filling system according to claim 1, wherein the blow molding machine (4), the transport lines (9a, 10a) together with the filling machines (5, 6) and the distribution unit (7) are arranged in a common clean room enclosure.

6. Filling system according to claim 5, further comprising a combining device (33) arranged within the common clean room enclosure for combining the transport lines onto a common discharge conveyor (34) for transporting the filled and sealed bottles (8a) in an upright position.

7. Filling system according to at least one of the previous claims, further comprising partial outlet conveyors (31, 32) which are connected downstream of the filling machines (5, 6) and are heightadjustable at least on the inlet side, for the vertical transport of the filled and closed bottles (8a).

8. Filling system according to at least one of the previous claims, wherein the central product distributor (41) is a valve node via which the product is fed to the individual filling valves of the filling machines (5, 6).

9. Filling system according to at least one of the previous claims, wherein the distribution device (7) comprises a distribution star (12) for alternately transferring every second bottle (8a) of the bottle stream (8) to the first and second transport lines (9a, 10a).

10. Filling system according to claim 9, wherein the distribution star (12) comprises clamps (15, 16) which can be actively opened by means of actuating elements (21, 22) rotating thereon and associated stationary actuating elements (26, 27), and wherein the actuating elements (21, 26) assigned to the first transport line (9a) are arranged on a first common actuation plane (24) and the actuating elements (22, 27) assigned to the second transport line (10a) are arranged on a second common actuation plane (24) above or below the first actuation plane so that the actuating elements are arranged so that they can be actuated independently of each other with respect to the actuation of the clamps.

11. Filling system according to at least one of the previous claims, wherein the transport lines (9a, 10a) each comprise at least one distribution delay star (13, 14) for reducing a first transport distribution (13b, 14b) during the division of the bottle stream (8) to a second transport distribution which is smaller in comparison during the filling of the bottles (8a).

12. Filling system according to at least one of the previous claims, wherein a sterilization unit (38) for sterilizing preforms (8b) is connected upstream of the blow molding machine (4).

13. Filling system according to at least one of the previous claims, wherein the closure cap distributor (51) is a cascade-shaped arrangement of feed channels (54, 55) which lead from the supply container (52) to the closure machines (29, 30).