An aseptic apparatus and process for filling and closing aluminium or glass receptacles

Abstract

An aseptic apparatus (1) for filling and closing Aluminium or glass receptacles (100) with ROPP screw caps (101), the aseptic apparatus (1) comprising: - a filling unit (13) configured to inject a product within the receptacles (100); - a ROPP capping unit (10) arranged downstream the filling unit (13) and being configured to apply on the receptacles (100) the ROPP screw caps (101) already sterilized; - an isolator (11) delimiting a controlled-contamination environment (12), the filling unit (13) and the ROPP capping unit (10) being arranged inside the isolator (11).

Description

[0001] The present invention relates to an aseptic apparatus and process for filling and closing Aluminium or glass receptacles.

[0002] Use of Aluminium as a material for producing containers has increased in the last years. In fact, Aluminium has a lower environmental impact than plastic, as well as higher recyclability properties.

[0003] In this context, the reference sector is the bottling of so-called "sensitive" food products, i.e., products which are particularly sensitive to bacteriological contamination and oxidation, such as isotonic beverages, juices, nectars, soft drinks, tea, milk-based beverages, coffee-based beverages, etc., for which avoiding possible microbiological contamination throughout all the packaging steps is of fundamental importance.

[0004] As is known, hot filling process is applied for filling Aluminium receptacles with sensitive products. Low acid products are also subject to a further heat-treatment process inside the receptacles (retort).

[0005] Hot filling process is also commonly used for filling glass receptacles with sensitive products.

[0006] Even if hot filling is a relatively easy process, closing Aluminium or glass receptacles requires complex capping machines.

[0007] In fact, Aluminium and glass receptacles shall be closed with Aluminium closures which are not originally threaded. The thread in a closure is created during its application on the receptacle by a capping head. Indeed, the threaded neck of the Aluminium or glass receptacle is used to generate an internal thread in the closure.

[0008] This is done by a ROPP capping machine (acronym for "Roll-On Pilfer-Proof" capping machine), which is quite more complex than a traditional capping machine used for applying closures to plastic bottles.

[0009] Due to its complexity and high number of components, a ROPP capping machine requires long and complicated cleaning and sterilizing steps. This raises significant issues especially in aseptic applications.

[0010] In fact, in a bottling line with aseptic technology it is of primary importance to control contamination in the various work stations (forming, filling, capping, etc.), thus it is essential to ensure adequate filtering of the fluids to be introduced into the controlled environment, correct management of the pressures of the various areas in order to control the path of any unwanted particles, correct monitoring of the environment, correct management and adequate quality of the cleaning and sterilization cycles of the internal parts of the machine (C.I.P., acronym for "Cleaning In Place" and S.I.P., acronym for "Sterilization In Place"), or of the external parts of the machine (C.O.P., acronym for "Cleaning Out of Place" and S.O.P., acronym for "Sterilization Out of Place").

[0011] In addition, ROPP capping machines are energy consuming and require complex and long maintenance operations.

[0012] The object of the present invention is to propose an aseptic apparatus and process for filling and closing Aluminium or glass receptacles in which sterility is assured, and at the same time the overall complexity and energy consumption are reduced.

[0013] Another object of the present invention is to propose an aseptic apparatus and process for filling and closing Aluminium or glass receptacles where maintenance operations are easier and quicker to be carried out.

[0014] Another object of the present invention is to propose an aseptic apparatus and process for filling and closing Aluminium or glass receptacles which allow to better preserve the organoleptic properties of the food products.

[0015] The stated technical task and specified aims are substantially achieved by an aseptic apparatus for filling and closing Aluminium or glass receptacles with ROPP screw caps, the aseptic apparatus comprising: a filling unit configured to inject a product within the receptacles; a ROPP capping unit arranged downstream the filling unit, said ROPP capping unit being configured to apply on said receptacles the ROPP screw caps already sterilized; an isolator delimiting a controlled-contamination environment, said filling unit and said ROPP capping unit being arranged inside the isolator.

[0016] Preferably, the aseptic apparatus further comprises a transfer star-wheel arranged between the filling unit and the ROPP capping unit. The transfer star-wheel is also located inside the isolator.

[0017] Preferably, the transfer star-wheel has a plurality of pockets for receiving bodies of the receptacles.

[0018] The aseptic apparatus further comprises a closures placing station arranged on a first zone of the transfer star-wheel and configured to place a ROPP screw cap onto a mouth of each receptacle.

[0019] More preferably, the closures placing station is also configured to press the ROPP screw caps onto the mouths of the receptacles.

[0020] The aseptic apparatus further comprises a treating device configured to sterilize the ROPP screw caps while they linearly advance along a conveying path inside the treating device.

[0021] In particular, the treating device is located above the closures placing station so that the sterilized ROPP screw caps are delivered to the closures placing station.

[0022] According to one embodiment of the invention, the treating device comprises: a box-like body; a treating chamber for the ROPP screw caps, which is inside the box-like body; a compartment located inside the box-like body and delimiting the treating chamber; a dispensing pipe configured to dispense a sterilizing substance inside the treating chamber.

[0023] In particular, the conveying path develops inside said treating chamber.

[0024] Preferably, the compartment is inclined so that the ROPP screw caps advance along the conveying path by force of gravity and / or by force exerted by the sterilizing substance.

[0025] The box-like body has an inlet for receiving the ROPP screw caps to be treated and an outlet for delivering the treated ROPP screw caps to the closures placing station.

[0026] For example, the box-like body has a substantially tubular shape, and the compartment consists in a tunnel.

[0027] According to one aspect of the invention, the dispensing pipe comprises a plurality of nozzles which are located close to the conveying path.

[0028] Preferably, the nozzles are distributed along the length of the dispensing pipe and are equally spaced.

[0029] According to another embodiment, the treating device is configured to sterilize the ROPP screw caps by means of radiations.

[0030] The ROPP capping unit comprises a plurality of ROPP capping heads. Each ROPP capping head is configured to apply the ROPP screw caps to the receptacles by creating an internal thread in the ROPP screw caps using threaded necks of the receptacles as a matrix.

[0031] The stated technical task and specified aims are substantially achieved by an aseptic process for filling and closing Aluminium or glass receptacles with ROPP screw caps inside an isolator delimiting a controlled-contamination environment, where the process comprises the following steps: sterilizing the ROPP screw caps; filling the receptacles with a product; applying on each filled receptacle a sterilized ROPP screw cap.

[0032] Before applying the sterilized ROPP screw cap on the corresponding filled receptacle, the process further comprises placing the sterilized ROPP screw cap onto a mouth of the filled receptacle.

[0033] The sterilization of the ROPP screw caps is performed by subjecting them to a sterilizing substance or to radiations.

[0034] Further characteristics and advantages of the present invention will more fully emerge from the non-limiting description of a preferred but not exclusive embodiment of an aseptic apparatus and process for filling and closing Aluminium or glass receptacles, as illustrated in the accompanying drawings, in which: figure 1 illustrates an aseptic apparatus for filling and closing Aluminium or glass receptacles, according to the present invention, in a schematic plant view; figure 2 illustrates the aseptic apparatus of figure 1, in a lateral perspective view; figure 3 illustrates a more detailed plant view of part of the aseptic apparatus of figure 1; figure 4 illustrates the treating device of the aseptic apparatus of figure 1, in a lateral view; figure 5 illustrates part of the treating device of figure 4, in a cross-sectional view; figure 6 illustrates an Aluminium or glass receptacle processed in the aseptic apparatus of figure 1; figure 7 illustrates a ROPP screw cap in a cross-sectional view.

[0035] With reference to the figures, number 1 denotes an aseptic apparatus for filling and closing Aluminium or glass receptacles 100, in particular bottles.

[0036] In this context, the aseptic apparatus 1 is also shortly referred to as "apparatus".

[0037] The apparatus 1 comprises a treating device 2 configured to treat ROPP screw caps 101 by means of a sterilizing substance or by radiations.

[0038] In particular, a ROPP screw cap 101 is a screw cap where the internal thread is formed by pressure against the neck 100b of a receptacle 100 upon the action a ROPP capping head, as it will be better explained later.

[0039] Originally, the ROPP screw cap 101 is a capsule comprising a base 101a and a lateral surface 101b which extends from the base 101a and defines therewith a cavity (see figure 7). Preferably, the base 101a is circular and the cavity is cylindrical, with the lateral surface 101b being the lateral surface of a cylinder.

[0040] On the opposite side of the base 101a, the ROPP screw cap 101 has an opening 101c destined to receive the neck 100b of a receptacle 100, which is externally threaded.

[0041] In particular, the ROPP screw caps 101 are made from Aluminium.

[0042] According to one embodiment of the invention, the treating device 2 comprises a box-like body 3 delimiting an environment 4. Inside the box-like body 3 there is a compartment 5 defining a treating chamber 6 for the ROPP screw caps 101.

[0043] In one embodiment of the invention, illustrated herewith, the treating device 2 is of the linear type.

[0044] According to a preferred embodiment, the box-like body 3 has a substantially tubular shape. The environment 4 defined by the tubular box-like body 3 is therefore shaped as a channel.

[0045] Preferably, the compartment 5 consists in a tunnel delimiting the treating chamber 6.

[0046] The treating device 2 further comprises at least one conveying path 7 for the ROPP screw caps 101 inside the treating chamber 6.

[0047] The ROPP screw caps 101 are made to advance linearly, e.g., one after the other, along the conveying path 7. In particular, the conveying path 7 is linear. For example, the conveying path 7 may be defined by rails.

[0048] Preferably, the box-like body 3 has an inlet 3a for receiving the ROPP screw caps 101 to be treated and an outlet 3b for delivering the treated caps 101 to a closures placing station 140 configured at least to place the treated caps 101 on the mouths 100a of the filled receptacles 100.

[0049] The compartment 5 is preferably inclined.

[0050] The treating device 2 further comprises a dispensing pipe 8 configured to dispense a sterilizing substance inside the treating chamber 6.

[0051] For example, the sterilizing substance is hydrogen peroxide. In particular, the sterilizing substance is gaseous. Alternatively, the sterilizing substance is liquid, such as peracetic acid.

[0052] According to one embodiment of the invention, the dispensing pipe 8 is an elongated pipe developing inside the box-like body 3.

[0053] Preferably, the dispensing pipe 8 has a substantially longitudinal extension inside the compartment 5.

[0054] The dispensing pipe 8 comprises a plurality of nozzles 9 that are located inside the treating chamber 6.

[0055] Preferably, the nozzles 9 are distributed along the length of the dispensing pipe 8.

[0056] More preferably, the nozzles 9 are equally spaced along the length of the dispensing pipe 8.

[0057] In particular, the nozzles 9 are arranged closed to the conveying path 7 so that the ROPP screw caps 101 advancing along the conveying path 7 receive the sterilizing substance.

[0058] The compartment 5 is preferably inclined. Thus, the ROPP screw caps 101 advance along the conveying path 7 by force of gravity and / or by force of a gas jet which can be a sterilizing substance.

[0059] The box-like body 3 is also preferably inclined, as illustrated in figure 4.

[0060] In this context, inclination of the compartment 5 or of the box-like body 3 is referred to a ground or floor which is substantially horizontal.

[0061] According to one aspect of the invention, the compartment 5 is not tight-sealed, thus the treating chamber 6 is not physically separated from the environment 4 defined by the box-like body 3.

[0062] Nevertheless, the compartment 5 serves for preventing the sterilizing substance from spreading away from the ROPP screw caps 101 during a treating phase.

[0063] In another embodiment of the invention (not illustrated), the treating device 2 is of the rotating type.

[0064] Accordingly, the treating device 2 comprises a box-like body 3 that has a substantially drum shape delimiting the environment 4.

[0065] In this embodiment, the treating device 2 comprises a rotating carousel located in the treating chamber 6 and a plurality of longitudinal rails integrally mounted on the rotating carousel.

[0066] The longitudinal rails are mutually parallel and are vertically arranged with respect to the ground. The longitudinal rails serve for housing the ROPP screw caps 101 arranged by force of gravity.

[0067] The apparatus 1 further comprises a ROPP capping unit 10 configured to apply the ROPP screw caps 101 on said receptacles 100. In particular, the ROPP screw caps 101 applied by the ROPP capping unit 10 have already been sterilized.

[0068] The apparatus 1 further comprises an isolator 11 adapted to define a controlled-contamination and sterile environment 12.

[0069] Advantageously, the ROPP capping unit 10 is located within the isolator 11, thus inside the controlled-contamination and sterile environment 12.

[0070] Preferably, the ROPP capping unit 10 is of the rotating type.

[0071] The apparatus 1 further comprises a filling unit 13, in particular of the rotating type, and at least one transfer star-wheel 14 arranged downstream the filling unit 13.

[0072] The ROPP capping unit 10 is arranged downstream the transfer star-wheel 14.

[0073] The filling unit 13 and the transfer star-wheel 14 are also located within the isolator 11, thus inside the controlled-contamination and sterile environment 12.

[0074] The apparatus 1 further comprises a sterilizing unit 16 for the receptacles 100, and a rinsing unit 17 arranged downstream the sterilizing unit 16.

[0075] In particular, the sterilizing unit 16 is configured to sterilize the receptacles 100 by means of hydrogen peroxide or peracetic acid.

[0076] The rinsing unit 17 is configured to rinse the receptacles 100 after the sterilization, for example by means of sterile water of sterile air.

[0077] The sterilizing unit 16 and the rinsing unit 17 are also located within the isolator 11, thus inside the controlled-contamination and sterile environment 12.

[0078] In thix context, saying that a unit (such as the ROPP capping unit 10, the filling unit 13, the transfer star-wheel 14, the closure placing station 140, the sterilizing unit 16, the rinsing unit 17) is located within the isolator 11 means that at least the part of said unit which handles or processes the receptacles 100, or which handles or processes the ROPP screw caps 101 is within the isolator 11. Thus, the receptacles 100 and the ROPP screw caps 101 are preserved from being contaminated.

[0079] By contrast, the actuating means associated to each of said units, which are used to actuate the movements of these parts are located outside the isolator 11, in a dirty environment.

[0080] The receptacles 100 are handled by their bottom 100d throughout the apparatus 1. In particular, the transfer star-wheel 14 has a plurality of pockets for receiving the bodies 100c of the receptacles 100. During the rotation of the transfer star-wheel 14, the bottoms 100d of the receptacles 100 slither on a lower support.

[0081] The apparatus 1 further comprises a closures placing station 140 arranged on a first zone of the transfer star-wheel 14.

[0082] The closures placing station 140 is preferably located downstream the filling unit 13 so as to receive the filled receptacles 100 from the filling unit 13.

[0083] In this context, the expression "A is downstream B" is used to indicate the position of element A with respect to element B relatively to the advancing path of the receptacles 100 throughout the apparatus 1.

[0084] The treating device 2 is located above the transfer star-wheel 13, so that the treating chamber 6 is also located above the transfer star-wheel 13.

[0085] In a preferred embodiment, illustrated wherewith, the outlet 3b of the box-like body 3 is located above the closures placing station 140 so that the sterilized ROPP screw caps 101 are delivered to the closures placing station 140 for being placed onto the mouths 100a of the receptacles 100.

[0086] As already explained, inclination of the compartment 5 or of the box-like body 3 is referred to a substantially horizontal ground G which is preferably the ground on which the filling unit 13 and the ROPP capping unit 10 are based.

[0087] The embodiment with the treating device 2 is preferred since the ROPP screw caps 101 are sterilized in-line within the apparatus 1.

[0088] In another embodiment, not shown, the treating device 2 is not present in the apparatus 1 but the ROPP screw caps 101 are sterilized in advance by other means. For example, the ROPP screw caps 101 may be presterilized outside the apparatus 1 by means of radiations, in particular gamma rays.

[0089] According to one embodiment, the closures placing station 140 is configured to place a ROPP screw cap 101 onto a mouth 100a of each receptacle 100.

[0090] More preferably, the closures placing station 140 is configured to place and press a ROPP screw cap 101 onto a mouth 100a of each receptacle 100.

[0091] According to one embodiment of the invention, each ROPP screw cap 101 is dropped from above (for example from the treating device 2) on the mouth 100a of the receptacle 100 by means of guides. In the bottling sector, this is referred-to as "a la volèe", or "on the fly". The pressing of the ROPP screw cap 101 on the mouth 100a is done by means of an upper guide or an inclined plane encountered by the receptacle 100 during movement thereof.

[0092] For example, the inclined plane is the lower plane of a circular sector located above the mouths 100a of the receptacles 100.

[0093] The "on the fly" gripping concept is well known, for example in non-aseptic capping machines and will therefore not be further detailed herein.

[0094] The actual application of the ROPP screw cap 101 to the corresponding receptacle 100 is performed by the ROPP capping unit 10.

[0095] In particular, the ROPP capping unit 10 comprises a plurality of ROPP capping heads. Each ROPP capping head is configured to apply a ROPP screw cap 101 previously placed (and preferably pressed) on the mouth 100a of an Aluminium or glass receptacle 100 in such a way as to definitively seal the receptacle 100. In particular, each ROPP capping head creates an internal thread in the ROPP screw cap 101 using the threaded neck 100b of the receptacle 100 as a matrix.

[0096] It must be remarked that ROPP capping per se is an established technology for closing glass receptacles, and in the last years it has also been used in closing Aluminium receptacles.

[0097] The apparatus 1 further comprises air supplying means 15 for supplying sterile air to the filling unit 13 and to the ROPP capping unit 10.

[0098] Preferably, the air supplying means 15 are configured to supply sterile air at a first pressure to the filling unit 13 and to supply sterile air at a second pressure to the ROPP capping unit 10, where the second pressure is lower than the first pressure.

[0099] In particular, the first pressure is comprised between 20 Pa and 50 Pa, and the second pressure is comprised between 5 Pa and 30 Pa.

[0100] In this context, the pressure values shall be intended as overpressure values, i.e., they are relative pressure values.

[0101] These different pressure values of overpressure are used to prevent contaminants from travelling towards critical areas. In fact, the overpressure established in the filling unit 13 (which is more critical) gives rise to an air flow towards the ROPP capping unit 10 (less critical), so limiting contaminants from travelling in an opposite direction, i.e., from the ROPP capping unit 10 to the filling unit 13.

[0102] The process for filling and closing Aluminium or glass receptacles according to the present invention is described below.

[0103] Preferably, the process is performed using the above-described apparatus 1.

[0104] Before starting the process, CIP-COP and SIP-SOP cycles are performed on all the units and equipments which are inside the controlled-contamination environment 12, i.e., under the isolator 11.

[0105] Accordingly, a plurality of nozzles is arranged within the controlled-contamination environment 12 for reaching all these parts. In particular, specific nozzles are arranged so as to dispense cleaning and sterilizing agents towards the ROPP capping heads, which are critical components.

[0106] After the CIP-COP and SIP-SOP cycles, the working process starts with the sterilization of the receptacles 100 in the sterilizing unit 16. Then, the receptacles 100 are rinsed by wet or dry rinsing in the rinsing unit 17.

[0107] The receptacles 100 are then filled with the product in the filling unit 13, that is inside the controlled-contamination and sterile environment 12.

[0108] The filled receptacles 100 are then discharged on the transfer star-wheel 14. In particular, they arrive in the closures placing station 140.

[0109] In the closures placing station 140 the filled receptacles 100 receive the sterilized ROPP screw caps 101 "on the fly".

[0110] As said, the ROPP screw caps 101 are preferably sterilized using the treating device 2, thus they are discharged from the outlet 3b of the box-like body 3 to the closures placing station 140.

[0111] Alternatively, the ROPP screw caps 101 are sterilized off-line.

[0112] The receptacles 100 with the ROP screw caps 101 placed (and preferably pressed) on their mouths 100a continue to travel on the transfer star-wheel 14, following an advancing path and arriving at the ROPP capping unit 10.

[0113] Here, the ROPP capping heads apply the ROPP screw caps 101 to the receptacles 100 by creating internal threads in the caps themselves.

[0114] The characteristics of the aseptic apparatus and process for filling and closing Aluminium or glass receptacles, according to the present invention, prove to be clearly indicated in the description provided.

[0115] Arranging the ROPP capping unit within the isolator allows to cap Aluminium or glass receptacles using aseptic technology.

[0116] This achieves a plurality of advantages with respect to traditional hot filling and retort process, such as: lower thermal stress on the food product, whose organoleptic properties are therefore better preserved; lower energy consumption, thus lower environmental impact; lower complexity and human workload; quicker and easier cleaning, sterilizing, and maintaining operations.

Claims

1. An aseptic apparatus (1) for filling and closing Aluminium or glass receptacles (100) with ROPP screw caps (101), the aseptic apparatus (1) comprising: - a filling unit (13) configured to inject a product within the receptacles (100); - a ROPP capping unit (10) arranged downstream the filling unit (13), said ROPP capping unit (10) being configured to apply on said receptacles (100) the ROPP screw caps (101) already sterilized; - an isolator (11) delimiting a controlled-contamination environment (12), said filling unit (13) and said ROPP capping unit (10) being arranged inside the isolator (11).

2. The aseptic apparatus (1) according to claim 1, further comprising: - a transfer star-wheel (14) arranged between the filling unit (13) and the ROPP capping unit (10), said transfer star-wheel (13) being located inside the isolator (11); - a closures placing station (140) arranged on a first zone of the transfer star-wheel (14) and configured to place a ROPP screw cap (101) onto a mouth (100a) of each receptacle (100); - a treating device (2) configured to sterilize the ROPP screw caps (101) while they linearly advance along a conveying path (7) inside the treating device (2), said treating device (2) being located above the closures placing station (140) so that the sterilized ROPP screw caps (101) are delivered to the closures placing station (140).

3. The aseptic apparatus (1) according to claim 2, wherein the closures placing station (140) is also configured to press the ROPP screw caps (101) onto the mouths (100a) of said receptacles (100).

4. The aseptic apparatus (1) according to claim 2 or 3, wherein the treating device (2) comprises: - a box-like body (3); - a treating chamber (6) for the ROPP screw caps (101) inside the box-like body (3), the conveying path (7) developing inside said treating chamber (6); - a compartment (5) located inside the box-like body (3) and delimiting said treating chamber (6); - a dispensing pipe (8) configured to dispense a sterilizing substance inside said treating chamber (6).

5. The aseptic apparatus (1) according to claim 4, wherein the compartment (5) is inclined so that the ROPP screw caps (101) advance along the conveying path (7) by force of gravity and / or by force exerted by the sterilizing substance.

6. The aseptic apparatus (1) according to claim 4 or 5, wherein the box-like body (3) has an inlet (3a) for receiving the ROPP screw caps (101) to be treated and an outlet (3b) for delivering the treated ROPP screw caps (101) to the closures placing station (140).

7. The aseptic apparatus (1) according to any one of claims 4 to 6, wherein the box-like body (3) has a substantially tubular shape, and the compartment (5) consists in a tunnel.

8. The aseptic apparatus (1) according to any one of claims 4 to 7, wherein said dispensing pipe (8) comprises a plurality of nozzles (9) which are located close to the conveying path (7).

9. The aseptic apparatus (1) according to claim 8, wherein said nozzles (9) are distributed along the length of the dispensing pipe (8) and are equally spaced.

10. The aseptic apparatus (1) according to claim 2 or 3, wherein the treating device (2) is configured to sterilize the ROPP screw caps (101) by means of radiations.

11. The aseptic apparatus (1) according to any one of claims 2 to 10, wherein the transfer star-wheel (14) has a plurality of pockets for receiving bodies (100c) of the receptacles (100).

12. The aseptic apparatus (1) according to any one of claims 2 to 11, wherein the ROPP capping unit (10) comprises a plurality of ROPP capping heads, each of said ROPP capping heads being configured to apply the ROPP screw caps (101) to the receptacles (100) by creating an internal thread in the ROPP screw caps (101) using threaded necks (100b) of the receptacles (100) as a matrix.

13. An aseptic process for filling and closing Aluminium or glass receptacles (100) with ROPP screw caps (101) inside an isolator (11) delimiting a controlled-contamination environment (12), the process comprising: - sterilizing the ROPP screw caps (101); - filling the receptacles (100) with a product; - applying on each filled receptacle (100) a sterilized ROPP screw cap (101).

14. The process of claim 13, wherein before applying the sterilized ROPP screw cap (101) on the corresponding filled receptacle (100), the process further comprises placing the sterilized ROPP screw cap (101) onto a mouth (100a) of said filled receptacle (100);15. The process of claim 13 or 14, wherein sterilizing the ROPP screw caps (101) is performed by subjecting them to a sterilizing substance or to radiations.

Images