PLANT AND METHOD FOR OPERATING A PLANT FOR MANUFACTURING FILLED PLASTIC CONTAINERS FROM STERILE PLASTIC PREFORMS

Description

[0001] The present invention relates to a system and a method for operating a system for manufacturing filled plastic containers, in particular filled beverage containers, from sterile plastic preforms. Such systems and methods for operating such systems have long been known in the art.

[0002] Typically, such systems include a forming device for transforming sterilized plastic preforms into plastic containers, which has a transport carrier that is movable and, in particular, rotatable about a central axis. A plurality of forming stations are usually arranged on the transport carrier for each forming a plastic preform into a plastic container by applying a flowable medium.

[0003] The contents, especially beverages, can only be filled into a container manufactured in this way once the container, particularly its interior, is sterile. Therefore, a sterilization device is typically provided to sterilize the containers, especially their interior (or inner wall). The filling process is usually carried out using a filling device to fill the plastic containers while they are transported, at least in sections and essentially along a circular path, around a central axis of the filling device.

[0004] The prior art includes systems and methods for operating such a system in which the sterilization process is carried out not on the fully formed containers, but on the unformed plastic preforms. The advantage of this approach is that the plastic preforms have a significantly smaller surface area than the (fully formed) plastic containers. This results in noticeably lower energy and media consumption. Furthermore, the preform does not yet have undercuts like the finished blow-molded bottle. Sterilization medium can therefore reach all areas more easily.

[0005] The disadvantages of the systems and methods for operating them, as currently known from the prior art, are that the systems require a large amount of installation space. For example, the internal prior art of the system includes a system in which the central axis of the forming device is more than 9 m away from the central axis of the filling device for systems with a forming device with 24 forming stations.

[0006] US 2016 / 257055 A1, US 2013 / 061557 A1 and US 2011 / 286899 A1 disclose systems for manufacturing filled plastic containers, in particular by means of a sterilization device for sterilizing at least one inner wall and / or outer wall of the plastic preforms, sterilized plastic preforms, with a transport device for transporting the plastic preforms and plastic containers formed from the plastic preforms by forming along a predetermined transport path through the system, with a forming device for forming the sterilized plastic preforms into plastic containers, wherein the transport device is suitable and intended for feeding the sterilized plastic preforms to the forming device, wherein the forming device has a rotatable transport carrier movable about a central axis (AB),a forming station, in which a plurality of forming stations are arranged for forming each of a plastic preform into a plastic container by applying a flowable medium, with a filling device for filling the plastic containers during their transport, at least in sections, substantially along a circular path around a central axis (AF) of the filling device, wherein the forming device and the filling device have a maximum distance (d) from each other with respect to their respective central axes (AB, AF).

[0007] US 2014 / 157726 A1 discloses a plant for manufacturing filled plastic containers from, in particular by means of a sterilization device for sterilizing at least one inner wall and / or outer wall of the plastic preforms, sterilized plastic preforms, with a transport device for transporting the plastic preforms and plastic containers formed from the plastic preforms by forming along a predetermined transport path through the plant, with a forming device for forming the sterilized plastic preforms into plastic containers, wherein the transport device is suitable and intended for feeding the sterilized plastic preforms to the forming device, wherein the forming device has a rotatable transport carrier movable about a central axis (AB).a forming station, in which a plurality of forming stations are arranged for forming each of a plastic preform into a plastic container by applying a flowable medium, with a filling device for filling the plastic containers during their transport, at least in sections, substantially along a circular path around a central axis (AF) of the filling device, wherein the forming device and the filling device have a maximum distance (d) to each other with respect to their respective central axes (AB, AF) of zero.

[0008] The present invention aims to overcome the disadvantages known from the prior art and to provide a system and a method for operating a system that requires less installation space or has a comparatively smaller footprint. This advantageously results in cost and space savings.

[0009] The object of the invention is achieved by the subject matter of the independent claims. Advantageous embodiments and further developments of the invention are the subject matter of the dependent claims.

[0010] An inventive system for producing filled plastic containers from plastic preforms, in particular by means of a sterilization device for sterilizing at least one inner wall and / or outer wall of the plastic preforms, has a transport device for transporting the plastic preforms and plastic containers produced from the plastic preforms by forming along a (fixed) predetermined transport path through the system.

[0011] The containers are preferably beverage containers and / or plastic or polyethylene terephthalate (PET) containers. Bottles are particularly preferred.

[0012] Preferably, the transport device is suitable and designed for the at least partial transport of the plastic preforms and / or plastic containers as they move through the system. Preferably, the transport device is suitable and designed for the (in particular, uninterrupted) complete transport of the plastic preforms and the plastic containers produced therefrom throughout the entire system. The transport device comprises, in particular, several different transport units, such as at least one and preferably a plurality of transport star(s) and / or feed star(s) and / or division star(s). In other words, the transport device is preferably designed as a multi-part system (consisting of a plurality of transport units), whereby the plastic preforms or the plastic containers are transferred from one transport unit to the next.

[0013] The system includes (at least, and preferably exactly) a forming device for forming the sterilized plastic preforms into (finished) plastic containers. The term "plastic container" (or "container") is used below specifically to refer to finished plastic containers formed from the plastic preforms (using the forming device).

[0014] The transport device is suitable and intended to feed the sterilized plastic preforms to the forming device, for example via an inlet star.

[0015] The forming device comprises a transport carrier that is movable about a central axis and, in particular, rotatable about the central axis. A plurality of forming stations are arranged on this carrier for forming individual plastic preforms into plastic containers by applying a flowable medium. Preferably, the plastic preforms are transported at least section by section around the central axis of the forming device essentially (at least section by section) along a circular path during their forming process (i.e., while they are individually arranged in one of the plurality of forming stations).

[0016] The plastic preforms are preferably fed to the forming device individually (successively). Each forming station can hold exactly one plastic preform to be formed.

[0017] The (common) (transport) carrier on which the multitude of forming stations are arranged is, in particular, a rotatable carrier and, more specifically, a blow molding wheel. The forming stations, especially the blow molding stations, each have a blow molding device, which preferably forms a cavity within which the plastic preforms can be expanded to form the plastic containers.

[0018] The blow molding devices are preferably multi-part and preferably comprise two blow mold halves and a base mold. These blow mold halves are preferably detachably arranged on a mold carrier shell or on the blow mold carriers. The blow mold carriers are pivotable relative to each other to open and close the blow molding devices. Furthermore, the blow mold carrier has locking mechanisms to lock the mold halves against each other during the blow molding process.

[0019] The forming device for transforming plastic preforms into plastic containers is preferably a blow molding machine (and / or a mold-filling machine). This means that the plastic preforms are first thermally conditioned in a heating section by means of a heating device and then expanded in a forming station, in particular a blow molding station, by being supplied with a liquid or gaseous medium (preferably compressed air). The flowable medium is preferably under pressure. For supplying the pressurized medium, the device preferably has a blow nozzle which can be sealed to an opening and / or inside an opening and / or a support ring of the plastic preforms and / or to a blow mold (device) in order to expand the plastic preforms with the liquid or gaseous medium.In other words, the blow nozzle can seal at the opening, but also at the support ring or the blow mold, or even inside the opening. A valve arrangement is also preferably provided, which controls the supply of blowing air to the plastic preforms.

[0020] Preferably, the plastic preforms are used for the forming process with different pressure levels, preferably according to a predetermined and preferably variable

[0021] Pressure curve, applied. For example, it is known that the plastic preforms are first subjected to a pre-blow pressure, then to at least one intermediate blow pressure, and finally to a final blow pressure.

[0022] The system includes a filling device for filling the plastic containers during their transport, at least in sections, essentially along a circular path around a central axis of the filling device. In other words, the containers are transported at least in sections along a circular path within or in the area of ​​the filling device, the center of which represents a central axis of the filling device, which is located, in particular, in a central area of ​​the filling device. Preferably, the filling device includes a carrier that is movable (about the central axis) and preferably rotatable, which transports the plastic containers—especially individually—at least in sections along the circular path.The section of the circle along which the plastic containers are moved preferably extends over a central angle of more than 180°, preferably more than 200°, and particularly preferably more than 270°.

[0023] Preferably, the filling device has a plurality of filling elements, wherein a filling element can be brought into fluid contact with a plastic container to be filled (transported at least sectionally along the circular path) in the filling device, and the plastic container can be filled by this filling element, or the filling element and the filling device are suitable and intended to fill the plastic container to be filled (with a predetermined filling material, such as a beverage) located in the filling device.

[0024] According to the invention, the forming device and the filling device have a maximum distance from each other with respect to their respective central axes. of 5.5 m, preferably of 5.3 m, and the forming device has a maximum number of 24 forming stations, or of 6.0 m, preferably of 5.6 m, and the forming device has more than 24 forming stations.

[0025] Preferably or alternatively, the forming device and the filling device have a maximum distance from each other with respect to their respective central axes. of 5.5 m, preferably of 5.3 m, in the case of a forming device with a maximum of 24 forming stations and / or of 6.0 m, preferably of 5.6 m, in the case of a forming device with more than 24 forming stations, on.

[0026] This results in a very small "footprint" for the facility.

[0027] In other words, in the case of a plant with a forming device which has a maximum number of 24 forming stations, the forming device is located a maximum of 5.5 m, preferably a maximum of 5.3 m, away from the filling device, viewed along the central axis of the forming device and the central axis of the filling device.

[0028] For example, in the case of a system with up to 16 forming stations, the distance between the forming device and the filling device could be in a range between 3 m and 5 m, preferably between 4.5 m and 1.8 m.

[0029] In the case of a plant with a forming device which has more than 24 forming stations (preferably between 25 and 30 forming stations and particularly preferably between 26 and 30 forming stations), the forming device is located a maximum of 6.0 m, preferably a maximum of 5.6 m, away from the filling device, viewed along the central axis of the forming device and the central axis of the filling device.

[0030] For example, in the case of a plant with more than 24 forming stations, the distance between the forming device and the filling device could be in a range between 4.5 m and 6 m, preferably between 5 m and 5.8 m and particularly preferably in a range between 5.2 m and 5.6 m.

[0031] In an advantageous embodiment, the system includes a sterilization device for sterilizing at least one inner wall (preferably a substantially, and particularly preferably, the entire inner surface) and / or one outer wall of a plastic preform to be formed. The sterilization device is suitable and designed to inactivate microorganisms and / or spores on the inner wall of the plastic preform to be formed. This offers the aforementioned advantage that a smaller (internal) surface area of ​​the plastic preform needs to be sterilized compared to the finished formed plastic container, thereby saving energy and media resources.

[0032] It is also conceivable that the sterilization device (or a further sterilization device) (particularly as part of the system) is provided which is suitable and intended to sterilize (in addition to the inner wall) at least a portion of an outer wall or an outer surface of the plastic preform, in particular to inactivate microorganisms and / or spores at least partially on the outer wall (preferably the entire outer surface) and preferably the entire surface (i.e., inner and outer surfaces) of the plastic preform to be formed. It is conceivable, for example, that (only) an opening area and / or a threaded area and / or a retaining ring is sterilized, so that recontamination of the sterilized inner wall area by a non-sterilised outer wall area can be prevented.

[0033] For sterilization, the sterilization device may be suitable and intended to use liquid hydrogen peroxide and / or a mixture of hot air and gaseous or vaporous hydrogen peroxide (in the gas phase and / or in the liquid phase) and / or concentrated hydrogen peroxide sprayed (preferably by means of spray nozzles and / or ultrasonic nebulization).

[0034] It is conceivable, for example, that spores are inactivated with a 35% hydrogen peroxide solution and water and hydrogen peroxide vapor saturated air (hydrogen peroxide vapor saturated air with a concentration of H₂O₂ in g / 100 g of dry air of at least 0.0228, preferably at least 0.0478, preferably at least 0.1002, preferably at least 0.1710, preferably at least 0.3656, preferably at least 0.7397), treatment temperature of at least 60°C.

[0035] Preferably, the sterilization device is arranged directly upstream of the forming device, so that no further treatment unit for the plastic preforms (except for their transport) is located between the forming device and the sterilization device. Preferably, the sterilization device is arranged between a heating device and the forming device. However, it would also be conceivable for the sterilization device to be arranged upstream of the oven or a heating device, or within the oven or a heating device.

[0036] Preferably, the sterilization device(s) for sterilizing the plastic preform(s) use only one sterilization medium, preferably H₂O₂. Further sterilization and / or decontamination processes in a heating device for warming the plastic preforms before their forming in the forming device are preferably no longer required. However, it is also conceivable that the sterilization device is located upstream of and / or within the heating device.

[0037] It is conceivable that UV lamps are used for a disinfection and / or sterilization and / or inactivation process. Furthermore, it is conceivable that an inactivation effect is achieved by irradiating a disinfectant applied to the plastic preform to be sterilized with hot air and / or IR radiation. In particular, it is also conceivable that the sterilization device is suitable and intended for thermal inactivation of microorganisms by means of IR treatment and / or heat.

[0038] It is also conceivable that chemical-thermal sterilization is carried out for sterilization (by the sterilization device(s)), in which a sterilizing agent is sprayed onto the plastic preforms at an elevated temperature and / or at an elevated temperature (e.g. peracetic acid or hydrogen peroxide) and / or preferably removed after an exposure time using sterile water or hot air.

[0039] Preferably, the sterilization device(s) is / are suitable and designed to reduce the number of living individuals (in the sterilized area) by at least six orders of magnitude (10⁻⁶). In particular, the sterilization device is suitable and designed to sterilize a given area to be sterilized in such a way that the residual content of viable microorganisms in a unit of the sterilized material is at most 10⁻⁶.

[0040] In a preferred embodiment, the forming device for forming plastic preforms into plastic containers comprises at least one sterilization maintenance device, which is suitable and intended to maintain a predetermined degree of sterilization and / or cleanliness of the inner wall of the plastic preforms to be formed and / or at least partially formed. The applicant has found that, despite such a space-consuming sterilization maintenance device, the maximum distances specified above are achievable.

[0041] The sterilization maintenance device could be designed (purely) mechanically, for example as a (particularly complete) enclosure or housing for the forming device, by means of which particles and dust from an external non-sterile environment (such as the production hall) are kept away from or shielded from the interior of the housing or enclosure. Additionally, it can be provided that a sterilizing agent (such as H₂O₂) is supplied, preferably continuously, at at least one position within the housing of the forming device and / or at a feed opening of the forming device, and that the plastic preforms to be formed are thus exposed to this agent (particularly before the forming stations are closed).

[0042] Preferably, the sterilization maintenance device is suitable and designed to maintain the sterilized areas of the plastic preform or a plastic container produced therefrom at a predetermined degree of sterilization and / or cleanliness of the inner wall and / or the outer wall (in particular the entire inner surface and / or the entire outer surface), which corresponds to at least a reduction in the germ count by at least 3 orders of magnitude, preferably at least 4 orders of magnitude, preferably at least 5 orders of magnitude and particularly preferably at least 6 orders of magnitude compared to a corresponding non-sterilised area of ​​the inner wall of the plastic preform or plastic container.Preferably, this predetermined degree of sterilization and / or purity is maintained during the forming process and particularly preferably throughout the entire forming device (especially by means of the sterilization maintenance device).

[0043] Preferably, the sterilization maintenance device is implemented by providing a cleanroom (described in more detail below), which preferably has a degree of sterilization and / or cleanliness in which, compared to the non-sterile environment, the number of viable microorganisms is reduced (killed and / or irreversibly inactivated) by at least six orders of magnitude. The number of living individuals (especially on and / or attached to the sterilized areas of the plastic preforms to be formed) is preferably reduced in the cleanroom by at least six orders of magnitude (i.e., to one millionth) (compared to the corresponding areas of the plastic preform in a non-sterile environment), so that the residual content of viable microorganisms in a unit of the sterilized material is preferably at most 10⁻⁶.

[0044] In a preferred embodiment, the system can be operated in a sterilization operation as well as in a separate production operation. Preferably, the sterilization operation differs from the production operation in that a sterilization medium is supplied to a feed line of the flowable medium intended for forming. This offers the advantage that a continuous supply of sterilization medium is not required; rather, the production operation only needs to be interrupted and the forming device sterilized during changeovers, thus conserving the sterilization medium.

[0045] Preferably, the forming device comprises a stationary part and a rotating part, wherein the fluid medium, which is used to expand the plastic preforms during the forming process by applying the fluid medium to them, is supplied from the stationary part of the forming device to the rotating part of the forming device via a rotary distribution device. Preferably, at least one (air) filter for reducing the microbial count and / or air filtration is provided in the fluid medium in the rotating part of the device and / or in an annular channel for (temporary) storage of the fluid medium.

[0046] Preferably, in the sterilization process, a valve is opened for the supply line of the fluid medium, which is preferably located in the stationary part of the forming device. This medium is then supplied with the sterilizing agent to sterilize the supply lines and / or the blow molding devices and / or the blow nozzle. Preferably, H₂O₂ (especially in gaseous form) and / or moist heat (steam sterilization; for example, pressurized saturated steam at 121°C for 15 minutes or 134°C for 3 minutes holding time) and / or dry heat (hot air sterilization, for example, moving hot air at approximately 180°C for 30 minutes exposure time) and / or a physicochemical low-temperature process (e.g., using ethylene oxide and / or formaldehyde-based steam and / or plasma sterilization) is used as the sterilizing agent.

[0047] In the production facility, it is preferable that no sterilizing agent is continuously supplied to the interior and / or the supply lines for fluid medium (used or to be used for the expansion or forming of the plastic containers).

[0048] Preferably, during sterilization, the sterilizing medium is fed into the insulator (of the forming device) via openings in an insulator wall (of an insulator of the forming device). Alternatively, it is preferably fed into the interior of the forming device (especially the cleanroom) via openings in an outer wall of the forming device, which separates (especially airtight) an interior space of the forming device from an external environment.

[0049] In a further advantageous embodiment, filtered air, and in particular HEPA-filtered and / or air filtered by means of a particulate filter (preferably high-performance particulate filter (EPA = Efficient Particulate Air) or HEPA (acronym for High-Efficiency Particulate Air / Arrestance) and / or high-performance particulate filter (ULPA abbreviation for "Ultra-Low Penetration Air")), is supplied to the production plant via the supply line for the forming of the plastic preforms.

[0050] Preferably, the forming device is a sterile forming device.

[0051] In a preferred embodiment, the blow-molded side parts are each arranged on a first mold carrier and a second mold carrier, which are movable relative to a pivot axis for opening and / or closing. The blow-molded side parts are preferably arranged interchangeably on the mold carriers. Preferably, the bottom part is also arranged, particularly interchangeably, on a bottom part carrier.

[0052] In a further preferred embodiment, the first mold carrier is opened and / or closed by a first angle and the second mold carrier is opened and / or closed by a second angle, wherein the first angle and the second angle are essentially identical.

[0053] Preferably, both mold carriers perform an identical movement. Both mold carriers are therefore preferably designed or arranged to be movable. This is particularly advantageous because it requires less space for the opening movement. The opening and / or closing movement of the mold carriers also contributes to the forming stations being arranged closer together, thus reducing the diameter of the transport carrier.

[0054] Preferably, the mold carriers are arranged or mounted on a stationary pivot axis or pivot shaft and are movable relative to it. The pivot axis preferably connects both mold carriers (mechanically). Advantageously, both mold carriers rotate about essentially the same angle relative to a fixed bearing axis of the pivot axis. Bearing elements in the form of sealed rolling bearings or sliding bearings are preferably arranged between the bearing axis and the mold carriers.

[0055] Preferably, the opening and closing movement of the mold carriers is mirrored around a geometric axis of symmetry. This opening and closing movement is preferably a pivoting movement, and in particular a pivoting movement about a predetermined angle.

[0056] The movement of the mold carriers is preferably controlled by at least one guide cam. Opening the mold carriers is particularly useful for inserting a plastic preform into the blow molding device and, after forming, for removing a formed plastic container from the blow molding device. Opening the mold carriers is also necessary for replacing blow mold components, such as the side panels and the bottom panel. Therefore, the opening and closing of the mold carriers is preferably performed within specific or predetermined angular ranges of the transport carrier.

[0057] The fact that the opening and / or closing movement of the first mold carrier by a first angle and the opening and / or closing movement of the second mold carrier by a second angle are essentially identical means that the opening and / or closing movement of the first mold carrier by the first angle and the opening and / or closing movement of the second mold carrier by the second angle differ from each other by no more than 3° to 10°, preferably by no more than 2° to 7°, and particularly preferably by no more than 1° to 5°. The opening angle between the two mold carriers is preferably between 0° and 150°.

[0058] In a preferred embodiment, the system comprises a cleanroom and / or sterile chamber, which is bounded by several walls and within which the plastic preforms are expanded to form the plastic containers. Preferably, the forming device includes a sealing device to seal the cleanroom from a non-sterile environment. In particular, this sealing device prevents non-sterile ambient air and germs from entering and contaminating the cleanroom. This offers the advantage that the risk of recontamination of the sterilized plastic preforms fed into the forming device by the cleanroom conditions can be minimized.

[0059] In other words, the blow molding machine, or the (transport) carrier and the blow mold arrangements, is preferably arranged within a cleanroom that separates the blow molding machine from a non-sterile environment. Drive devices for closing, locking, and / or opening the blow molds are preferably arranged outside the cleanroom.

[0060] The blow molding equipment is preferably transported within the cleanroom. The cleanroom is preferably bounded by at least one stationary wall and one wall moving relative to this stationary wall. For example, the transport carrier on which the blow molding equipment is arranged can already have or form one of these walls, and in particular the moving wall. Advantageously, the cleanroom is designed in a ring or torus shape around the blow molding or forming stations and / or the transport path of the plastic containers.

[0061] In a further preferred embodiment, the sealing device has at least one circumferential channel that can be filled with a liquid and into which a circumferential wall projects, wherein this wall is preferably at least one blade and particularly preferably exactly one blade. It is therefore proposed to use a so-called water seal for sealing the cleanroom, and in particular a simple water seal which has exactly one blade that immerses in the flowable medium and thus separates a non-sterile area from the sterile area. By using a simple water seal, as opposed to a double water seal, a smaller footprint of the system can also be achieved, as it requires less space.

[0062] In particular, the sealing device preferably has a simple water lock which has exactly one sword that immerses in a circumferential channel filled with a liquid and thus separates a non-sterile area from the sterile area.

[0063] The circumferential wall of the sealing device is preferably rotatable relative to the channel. Preferably, the rotational movement of this wall is coupled to the rotational movement of the transport carrier. This wall is thus preferably a circumferential blade that forms part of the water seal or hydraulic seal. Particularly preferably, this wall is immersed in the liquid contained in the channel. Conversely, it would also be conceivable for the channel to be rotatable and the circumferential wall to be stationary.

[0064] Preferably, the circumferential channel is divided by the circumferential wall of the sealing device into a radially inner channel section and a radially outer channel section, wherein the sword preferably immerses in the liquid in an area between the inner channel section and the outer channel section.

[0065] In an advantageous embodiment, the transport device has at least three transport units in a section of the transport path between the forming device and the filling device, each with a transport carrier movable about a central axis, in particular rotatable, such as transport stars and / or indexing stars and / or feed stars. Achieving a small footprint for the system is also influenced by the need for a sufficiently long transport path between the forming device and the filling device, allowing the freshly formed plastic containers to cool and / or harden sufficiently before filling, thus ensuring high quality of both the product being filled and the filled container.

[0066] Preferably, the forming device and / or the filling device is designed as a rotary or carousel, which preferably has a plurality of forming stations or blowing stations and transports the blow forming devices (in the case of the forming device) and the filling elements (in the case of the filling device) around the respective central axis along a circular line.

[0067] After the forming or expansion process is complete, the finished plastic containers are removed from the forming device of the plastic preforms into plastic containers by a removal device for receiving the plastic containers, which can be designed as a rotatable transport star, in particular as a division distortion star.

[0068] In a preferred embodiment, the system includes a ventilation device for regulating at least one predetermined property of the atmosphere prevailing in the area where the plastic preforms are formed into plastic containers. This property is characteristic of a physical quantity, such as air pressure and / or air temperature and / or humidity and / or air density, a flow velocity, and / or a physicochemical quantity, such as a characteristic of air composition, and / or an air cleanliness quantity, such as a degree of purity and / or a degree of sterilization. Viewed from above, the ventilation device is arranged between the forming device and the filling device. Such ventilation devices offer the advantage of maintaining the predetermined degree of purity and / or degree of sterilization described above.For example, an overpressure can be maintained inside the forming device compared to the surrounding environment (outside an enclosure or housing), so that essentially no air flows from the external environment into the interior of the forming device. Furthermore, fresh and / or clean and / or filtered air can be supplied continuously, allowing for a controlled airflow direction.

[0069] Such ventilation devices also require a comparatively large installation space. Preferably, the ventilation device is arranged above the forming device and, in particular, laterally above the forming device. "Laterally" here means, in particular, that the entire ventilation device is arranged between the forming device and the filling device (with respect to their respective central axes). Preferably, the ventilation device, viewed from above, does not extend beyond an edge region of the forming device opposite the filling device. Preferably, the ventilation device, viewed from above, does not extend beyond the filling device. Most preferably, the ventilation device is arranged—viewed from above—such that there is no overlap with the filling device.This is advantageous because the filling device itself requires a large number of media inlets and / or outlets, which are preferably arranged above the filling device.

[0070] The ventilation device preferably provides the fluid medium used for forming the plastic preforms, in particular the blowing air, by means of which the plastic preforms are subjected to expansion. Additionally or alternatively, the ventilation device (in particular of the forming device) preferably provides control air, which is used in particular for controlling various (especially pneumatic) elements (of the forming device), and / or sterile air.

[0071] In particular, the system can be arranged in a corner configuration or in a linear configuration and, in both the corner and linear configurations, exhibit the maximum values ​​specified above for the distance between the forming device and the filling device (seen with respect to their central axes). A corner configuration is preferred.

[0072] A corner installation of the system is understood to mean in particular an arrangement in which a main container transport direction with a connecting direction, which extends essentially from the central axis of the forming device to the central axis of the filling device, encloses an angle which is greater than 15°, preferably greater than 20° and particularly preferably greater than 28°.

[0073] If, with respect to a process angle of the forming device, a zero angle is defined as the angular position that is (essentially) exactly (midway) between a feeding device (such as a feed star) that feeds the plastic preforms to be formed into the forming device and a discharge device that removes the finished plastic preforms from the forming device, then the main container transport direction is preferably understood to be a 270° direction with respect to this zero angle (measured counterclockwise). This is illustrated in the figures.

[0074] A main container transport direction is understood to mean, in particular, a connection direction from a center of gravity and / or a center point and / or a central axis of a feeding device, especially a feed star of the forming device, and the center of gravity and / or a center point and / or a central axis of a discharge device, which removes the finished formed containers from the forming device. If the processing units such as the forming device are disregarded, the containers are transported along a connecting line (along the connection direction) from the feed star or the feeding device to the discharge device (or along a circle around it).

[0075] A linear arrangement of the system is to be understood in particular as an arrangement in which a main container transport direction with a connecting direction which extends essentially from the central axis of the forming device to the central axis of the filling device includes an angle which is not greater than 10°, preferably not greater than 8° and particularly preferably not greater than 5°.

[0076] In a preferred embodiment, when the system is installed in a corner configuration and includes a forming device, preferably with a forming device having a maximum of 24 forming stations, the forming device and the filling device have a maximum distance of 4.5 m, preferably 4.2 m, and particularly preferably 4.05 m from each other with respect to their respective central axes. This allows for an even smaller distance between the filling device and the forming device when installed in a corner configuration. It is also conceivable that a system installed in a corner configuration could have more than 24, for example, 30 forming stations.

[0077] In a preferred embodiment, when the system is installed in a corner configuration and includes a forming device with a maximum of 16 forming stations, the forming device and the filling device have a maximum distance of 4 m, preferably 3.8 m, and particularly preferably 3.5 m from each other with respect to their respective central axes. This allows for an even smaller distance between the filling device and the forming device when the system is installed in a corner configuration, even with forming devices having a smaller maximum number of forming stations.

[0078] In the case of forming devices with 4 to 16 forming stations, a diameter of the transport carrier of less than 2 m is preferred. Particularly preferred is the arrangement of a plurality of forming stations, selected from a number between 4 and 16, on a transport carrier with a diameter of greater than or equal to 0.5 m and less than or equal to 2 m.

[0079] In the case of forming devices with 17 to 35 forming stations, a diameter of the transport carrier of less than 3 m is preferred. Particularly preferred is the plurality of forming stations, selected from a number of forming stations between 17 and 35, arranged on a transport carrier with a diameter of greater than or equal to 2.1 m and less than or equal to 3 m.

[0080] It is therefore preferentially proposed to increase the number of forming stations on a transport carrier or to arrange more forming stations on a smaller transport carrier than before. This also allows for a smaller footprint or space requirement of the system and a closer proximity of the forming device to the filling device (with respect to their central axes) compared to the blow molding machines previously known from the applicant's prior art. In the prior art, the (pitch circle) diameter of the transport carrier is very large in relation to the number of forming stations arranged on the transport carrier. For example, it is known from the applicant's internal prior art that only 12 to 16 forming stations are arranged on a transport carrier with a diameter of 2.3 m, and 20 to 24 forming stations on a carrier with a diameter of 3.4 m.

[0081] The individual forming stations arranged on the transport carrier preferably have a distance between 0.05 m and 1 m, more preferably between 0.06 m and 0.8 m, and particularly preferably between 0.07 m and 0.5 m from each other. Particularly preferably, if the diameter of the transport carrier is less than 2 m, the individual forming stations have a distance between 0.08 m and 0.6 m, more preferably between 0.1 m and 0.5 m from each other, or if the diameter of the transport carrier is less than 3 m, a distance between 0.05 m and 0.2 m, more preferably between 0.07 m and 0.18 m from each other. The exact distance between the forming stations depends on the exact diameter of the transport carrier and the number of forming stations.For example, the distance between individual forming stations is approximately 0.12 m for a transport carrier with a diameter of 1.7 m and 14 forming stations, and approximately 0.1 m for a transport carrier with a diameter of 2.3 m and 22 forming stations. This allows more forming stations to be arranged on comparatively smaller diameters, which advantageously enables the forming device to be positioned closer to the filling device.

[0082] According to the invention, the ratio between the diameter of the transport carrier and the number of forming stations is less than 0.14, preferably less than 0.13, and particularly preferably less than 0.12. These ratios are advantageous because they allow for an optimal ratio between the number of forming stations and the size of the transport carrier, enabling the carrier to be chosen as small as possible and thus reducing the space requirement.

[0083] By adhering to these parameters, several stations can be arranged on a smaller platform or transport carrier. This also allows the dimensions of the forming device to be reduced for a given number of forming stations, enabling the central axes of the forming device and the filling device to be positioned closer together.

[0084] A preferred ratio is one between the diameter of the transport carrier and the number of forming stations greater than 0.35, preferably greater than 0.2.

[0085] A ratio between the diameter of the transport carrier and the number of forming stations is particularly preferred if it is less than 0.14 or greater than 0.2.

[0086] In a preferred embodiment, a forming station has a station output of between 2500 and 2800 plastic containers per hour. In other words, between 2500 and 2800 plastic containers can be formed per hour with one forming station.

[0087] In another preferred embodiment, the device has a system output of between 10,000 and 85,000 plastic containers per hour. The system output depends in particular on the number of forming stations in the device.

[0088] Preferably, the blow molding machine is a stretch blow molding machine, meaning that the preforms are stretched longitudinally before and / or during expansion by means of a stretching device, in particular a rod-shaped body, such as a stretching bar. The forming stations, especially the blow molding stations, each have stretching devices, in particular rod-shaped bodies, such as stretching bars, which can be inserted into the plastic preforms and stretch them longitudinally. The stretching devices, in particular the rod-shaped bodies, such as the stretching bars, preferably have an electric drive.

[0089] In an advantageous embodiment, the forming device for forming plastic preforms into plastic containers comprises, and preferably each forming station, in particular each blow molding station, has a temperature control unit suitable and designed to temperature control parts of the blow molding device, in particular to heat parts of the blow molding device. Preferably, this heating is carried out using electrical energy or using a flowable, and in particular liquid, temperature control medium. For example, hot oil or water can be used to temperature control the side parts of the blow mold and / or the bottom part of the blow mold. This temperature control can be achieved by means of channels arranged in the blow mold itself and / or by means of channels arranged in blow mold trays and / or in a blow mold carrier.

[0090] In an advantageous embodiment, the system comprises at least one heating device for heating preforms, injection molding devices, particularly for producing the (plastic) preforms, labeling units for labeling the filled (plastic) containers, (further) sterilization units, sealing device(s) for sealing the filled plastic containers, or the like. A combination of one or more of these devices or units in the system is also preferred.

[0091] Preferably, the system includes an injection molding device (in particular for producing the plastic preforms). Preferably, the entire path between the injection molding device and the filling device and / or a capping device (which caps the containers filled by the filling device) is kept sterile and / or is part of the cleanroom. In particular, in the case of a system with an injection molding device, the entire path between the injection mold and the capper is kept sterile.

[0092] Preferably, the heating device for heating plastic preforms is arranged upstream of the forming device for forming the plastic preforms into plastic containers in the transport direction of the plastic preforms.

[0093] The plastic preforms to be heated are preferably introduced into the heating device via an insertion device. Within the heating device, they are transported along a predetermined transport path by means of a transport device. A plurality of heating boxes or heating elements are arranged in the heating device, particularly along straight transport sections, by means of which the plastic preforms are heated, in particular according to a predetermined temperature profile. This temperature profile can be variable along the longitudinal direction of the plastic preform.

[0094] After passing through the heating device, the plastic preforms are transported, preferably by means of a transport device which can be designed as a transport star and which has receiving elements for receiving the plastic preforms, to the device for forming the plastic preforms into plastic containers and placed into an (open) blow molding device.

[0095] The present invention further relates to an arrangement for a filling device relative to a forming device in a system for producing filled plastic containers, in particular by means of a sterilization device for sterilizing at least one inner wall and / or outer wall of the plastic preforms, or sterilized plastic preforms. The system includes a transport device for transporting the plastic preforms and the plastic containers produced from the plastic preforms by forming them along a predetermined transport path through the system.

[0096] Furthermore, the system includes the forming device for forming the sterilized plastic preforms into plastic containers, wherein the transport device is suitable and intended for feeding the sterilized plastic preforms to the forming device, wherein the forming device has a transport carrier movable about a central axis and in particular rotatable, on which a plurality of forming stations for forming each of a plastic preform into a plastic container by applying a flowable medium is arranged.

[0097] The system includes a filling device for filling the plastic containers during their transport, which takes place at least in sections and essentially along a circular path, around a central axis of the filling device.

[0098] According to the invention, the forming device and the filling device are arranged such that they have a maximum distance from each other with respect to their respective central axes. of 5.5 m, preferably of 5.3 m, and the forming device has a maximum number of 24 forming stations, or of 6.0 m, preferably of 5.6 m, and the forming device has more than 24 forming stations.

[0099] A preferred arrangement of the forming device and the filling device is such that they have a maximum distance from each other with respect to their respective central axes. of 5.5 m, preferably of 5.3 m, in the case of a forming device with a maximum number of 24 forming stations and / or of 6.0 m, preferably of 5.6 m, in the case of a forming device with more than 24 forming stations.

[0100] The present invention further relates to a method for operating a system for manufacturing filled plastic containers, in particular by means of a sterilization device for sterilizing at least one inner wall and / or outer wall of the plastic preforms. The system includes a transport device which transports the plastic preforms and the plastic containers produced from the plastic preforms by forming along a predetermined transport path through the system.

[0101] The (to be operated) plant further comprises a forming device which forms the sterilized plastic preforms into plastic containers, wherein the transport device feeds the sterilized plastic preforms to the forming device, wherein the forming device has a transport carrier movable about a central axis and in particular rotatable, on which a plurality of forming stations for forming each of a plastic preform into a plastic container by applying a flowable medium is arranged.

[0102] The (to be operated) plant has a filling device for filling the plastic containers during their transport, at least in sections, essentially along a circular line around a central axis of the filling device.

[0103] According to the invention, the forming device and the filling device have a maximum distance from each other with respect to their respective central axes. of 5.5 m, preferably of 5.3 m, and the forming device has a maximum number of 24 forming stations, or of 6.0 m, preferably of 5.6 m, and the forming device has more than 24 forming stations.

[0104] Preferably, the forming device and the filling device have a maximum distance from each other with respect to their respective central axes. of 5.5 m, preferably of 5.3 m, in the case of a forming device (8) with a maximum number of 24 forming stations and / or of 6.0 m, preferably of 5.6 m, in the case of a forming device (8) with more than 24 forming stations.

[0105] It is therefore also proposed within the framework of the inventive method that a space-saving design is achieved by a maximum distance between the forming device and the filling device.

[0106] The plant described above is specifically designed and intended to carry out and operate the described process; that is, all features implemented for the plant described above are also disclosed for the process described here, and vice versa. Furthermore, in a preferred method for operating the plant, those process steps are carried out individually or in combination which were described above within the context of the plant as suitability features for implementation ("suitable and / or intended").

[0107] Further advantages and embodiments are shown in the attached drawings: These show: Fig. 1 is a schematic representation of a system according to the invention for producing filled plastic containers according to a preferred embodiment in a corner arrangement; and Fig. 2 is a schematic representation of a system according to the invention for producing filled plastic containers according to a preferred embodiment in a linear arrangement.

[0108] Fig. 1 shows a schematic representation of a plant 1 according to the invention for producing filled plastic containers 10 according to a preferred embodiment in a corner arrangement.

[0109] Plastic preforms 11 are preferably heated by means of a heating device 24, shown schematically here, and sterilized by means of a sterilizing device 22, also shown schematically here (at least a particularly complete inner wall area and preferably a particularly complete outer wall area and / or mouth area).

[0110] A feeding device 6, such as a star feeder, feeds the plastic preforms to be formed to the forming device 8, in which they are transported at least section by section along a (shown) circular path around the central axis AB, while within a forming station they are exposed to a fluid medium and thereby expanded. Finally, after the forming process has been completed, they are removed from the forming device by a discharge device 13, preferably a splitting star feeder.

[0111] The reference symbol N designates a 0° process angle of the forming device as the reference direction, indicating a (central) (angular) position between the feed position of the plastic preforms and the discharge position of the plastic containers. A direction perpendicular to this (270°) is designated or defined as the main container transport direction B. This direction indicates the main direction of movement in which the plastic preforms (then as containers) are essentially transported to the next processing device (apart from their fundamentally circular transport).

[0112] The plastic container is transferred via at least one and preferably via a plurality of transport stars 14 (of the transport device 2) to a feeding device (e.g., a splitting star wheel) 16, which in turn transfers the plastic container to be filled to the filling device 12. In the filling device, the plastic containers to be filled are transported around a central axis AF, in particular (at least sectionally) along a circular path.

[0113] The reference numeral V indicates the connection direction between the central axis AB of the forming device 8 and the central axis AF of the filling device 12.

[0114] The distance d between the central axis AB of the forming device 8 and the central axis AF of the filling device 12 is a maximum of 5.5 m, preferably a maximum of 5.3 m, in the case of a forming device 8 with a maximum of 24 forming stations and / or a maximum of 6.0 m, preferably a maximum of 5.6 m, in the case of a forming device 8 with more than 24 forming stations.

[0115] Fig. 1 This represents a preferred corner configuration, which is characterized by the fact that the angle α, which the main container transport direction B encloses with the connection direction V, is greater than 15°, preferably greater than 20° and particularly preferably greater than 28°.

[0116] Reference numeral 18 designates a discharge device (such as a discharge star) for removing the filled plastic containers from the filling device 12.

[0117] Fig. 2Figure 1 shows a schematic representation of a plant 1 according to the invention for producing filled plastic containers 10 according to a preferred embodiment in a preferred linear arrangement (as opposed to the corner arrangement in Fig. 1 ). Identical reference symbols denote identical or similarly functioning elements, devices, or sizes.

[0118] A linear arrangement of the system 1 is to be understood in particular as an arrangement in which the main container transport direction B with the connection direction V encloses an angle which is not greater than 10°, preferably not greater than 8° and particularly preferably not greater than 5°.

[0119] Reference numeral 20 further denotes a schematic representation of a ventilation device (in particular a ventilation unit) which (viewed in the connection direction V) is arranged between the forming device 8 and the filling device 12.

[0120] Unlike the one in Fig. 1 Annex 1 shown here indicates that Fig. 2 The depicted system 1 includes a transport device 2 with a plurality (here 7) of transport units 14 between the discharge device 13 and the feed device 16. Reference symbol list

[0121] 1 Plant 2 Transport device 8 Forming device 10 Plastic container 11 Plastic preform 13 Discharge device 14 Transport star 16 Feeding device 20 Ventilation device 22 Sterilization device 24 Heating device AB Center axis Forming device AF Center axis AF B Main transport direction N Zero angle V Connection direction

Claims

1. A system (1) for producing filled plastic containers (10) from sterilized plastic preforms, in particular by a sterilization apparatus (22) for sterilizing at least one inner wall and / or outer wall of the plastic preforms (11), comprising a transport device (2) for transporting the plastic preforms (11) and plastic containers (10) produced from the plastic preforms (11) by forming, along a predetermined transport path through the system (1), comprising a forming apparatus (8) for forming the sterilized plastic preforms (11) into plastic containers (10), wherein the transport device (2) is suitable and intended for supplying the sterilized plastic preforms (11) to the forming apparatus (8), wherein the forming apparatus (8) has a transport carrier which can be rotated about a central axis (AB) on which transport carrier a plurality of forming stations each for forming a plastic preform (11) into a plastic container (10) by applying a flowable medium is arranged, comprising a filling apparatus (12) for filling the plastic containers (10) during their at least sectional transport substantially along a circular line about a central axis (AF) of the filling apparatus (12), wherein the forming apparatus (8) and the filling apparatus (12) have a maximum distance (d) from one another in relation to their respective central axes (AB, AF) - of 5.5 m, preferably of 5.3 m, and the forming apparatus (8) has a maximum number of 24 forming stations or - of 6.0 m, preferably of 5.6 m, and the forming apparatus (8) has more than 24 forming stations, wherein a ratio between a diameter of the transport carrier and a number of forming stations is smaller than 0.14.

2. The system (1) according to claim 1, characterized in that the system (1) has a sterilization apparatus (22) for sterilizing at least one inner wall and / or outer wall of a plastic preform (11) to be formed, wherein the sterilization apparatus (22) is suitable and intended for inactivating microorganisms and / or spores on the inner wall and / or outer wall of the plastic preform (11) to be formed.

3. The system (1) according to at least one of the preceding claims, characterized in that the forming apparatus (8) for forming plastic preforms (11) into plastic containers (10) has at least one sterilization maintenance apparatus which is suitable and intended for maintaining a predetermined degree of sterilization and / or degree of purity of the inner wall of the plastic preforms to be formed and / or of the at least partially formed plastic preforms (11).

4. The system (1) according to at least one of the preceding claims, characterized in that the system (1) can be operated in a sterilization operation and in a production operation different therefrom, wherein the sterilization operation differs from the production operation in that in the sterilization operation, a sterilizing medium is supplied to a supply line of flowable medium provided for forming.

5. The system (1) according to the preceding claim, characterized in that in the production operation, filtered air and in particular HEPA-filtered air is supplied via the supply line for forming the plastic preforms.

6. The system (1) according to at least one of the preceding claims, characterized in that an opening and / or closing movement of a first mold carrier (8a) takes place by a first angle and an opening and / or closing movement of a second mold carrier (8b) takes place by a second angle, wherein the first angle and the second angle are substantially identical.

7. The system (1) according to one of the preceding claims, characterized in that the system (1) has a clean room which is delimited by several walls and within which the plastic preforms (11) are expanded to form the plastic containers (10), and in that the forming apparatus has a sealing apparatus in order to seal the clean room from a non-sterile environment.

8. The system (1) according to the preceding claim, characterized in that the sealing device has a single water lock, which has exactly one blade, which dips into a circumferential channel filled with a liquid and thus separates a non-sterile region from the sterile region.

9. The system (1) according to at least one of the preceding claims, characterized in that a corner arrangement of the system (1) is present in which a main container-transport direction (B) encloses an angle (α) greater than 10°, preferably greater than 20° and particularly preferably greater than 28°, with a connection direction (V) which extends substantially from the central axis (AB) of the forming apparatus (8) to the central axis (AF) of the filling apparatus (12).

10. The system (1) according to at least one of the preceding claims, characterized in that the forming station (4) has a station capacity of between 2500 and 2800 plastic containers (10) per hour.

11. The system (1) according to at least one of the preceding claims, characterized in that the system (1) has a system capacity of between 10,000 and 85,000 plastic containers (10) per hour.

12. The system (1) according to at least one of the preceding claims, characterized in that in a section of the transport path between the forming apparatus (8) and the filling apparatus (12), the transport device (2) has at least three transport units with a, in particular rotatable, transport carrier, such as transport starwheels (14) and / or pitch delay starwheels (13), which can be moved about respective central axes.

13. The system (1) according to at least one of the preceding claims, characterized in that the forming apparatus (8) and / or the filling apparatus (12) is / are designed as a carousel-type machine.

14. The system (1) according to at least one of the preceding claims, characterized in that the system (1) has a ventilation apparatus (20) for regulating at least one predetermined property variable of an atmosphere prevailing in the region of the forming of the plastic preforms (11) into plastic containers (10), wherein the property variable is characteristic of a physical variable, such as an air pressure and / or an air temperature and / or an air humidity and / or an air density, a flow rate, and / or a physicochemical variable, such as a variable characteristic of an air composition, and / or of an air purity variable, such as a degree of purity and / or a degree of sterilization, and wherein, in a plan view of the system (1), the ventilation apparatus is arranged between the forming apparatus (8) and the filling apparatus (12).

15. A method for operating a system (1) for producing filled plastic containers (10) from sterilized plastic preforms, in particular by a sterilization apparatus (22) for sterilizing at least one inner wall and / or outer wall of the plastic preforms (11), comprising a transport device (2), which transports the plastic preforms (11) and plastic containers (10) produced from the plastic preforms (11) by forming, along a predetermined transport path through the system (1), comprising a forming apparatus (8), which forms the sterilized plastic preforms (11) into plastic containers (10), wherein the transport device (2) supplies the sterilized plastic preforms (11) to the forming apparatus (8), wherein the forming apparatus (8) has a transport carrier which can be rotated about a central axis (AB) on which transport carrier a plurality of forming stations each for forming a plastic preform (11) into a plastic container (10) by applying a flowable medium is arranged, comprising a filling apparatus (12) for filling the plastic containers (10) during their at least sectional transport substantially along a circular line about a central axis (AF) of the filling apparatus (12), wherein the forming apparatus (8) and the filling apparatus (12) have a maximum distance (d) from one another in relation to their respective central axes (AB, AF) - of 5.5 m, preferably of 5.3 m, and the forming apparatus (8) has a maximum number of 24 forming stations or - of 6.0 m, preferably 5.6 m, and the forming apparatus (8) has more than 24 forming stations, wherein a ratio between a diameter of the transport carrier and a number of forming stations is smaller than 0.14.