Aseptic molding device

Abstract

To provide an aseptic molding device that can deliver a high sterilization effect with a simple structure.SOLUTION: An aseptic molding device 20 aseptically molds sterilized containers that have been subjected to a sterilization process. In the aseptic molding device 20, a sterilization mechanism 50 is configured to complete sterilization of the containers only by sterilization treatment at the preform stage. An oven area A1 is provided with a temperature increasing area A2 and an in-oven sterilization area A3 that is adjacent to the downstream side of the temperature increasing area A2 in which a final temperature increasing heater 33 on the conveying path is installed and performs the sterilization treatment on the preform P. A preform transport mechanism 40 transports the preform P through the temperature increasing area A2 and the in-oven sterilization area A3 while maintaining the same preform P held by the same holder 41a.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to an aseptic molding apparatus that aseptically molds sterilized containers that have been subjected to a sterilization treatment, and in particular to an aseptic molding apparatus that is incorporated into an in-line blow type aseptic filling system that performs all processes from container molding to filling and sealing the contents. [Background technology]

[0002] 2. Description of the Related Art Conventionally, there has been known an in-line blow type filling system that performs an integrated process from forming containers by blow molding to filling and sealing the contents within the same factory (see, for example, Patent Document 1).

[0003] In such a filling system, the containers must be thoroughly sterilized before being transported to a filling device maintained in a sterile environment. In the filling system described in Patent Document 1, in addition to a sterilization process at the preform stage before the container is molded by blow molding, a sterilization process is also performed at the container stage after blow molding. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2010-202284 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, when sterilization is performed at the container stage, there are problems such as the need for a larger sterilization mechanism, the need for a larger amount of sterilant because the container has a larger surface area than the preform, and the sterilization time being longer. Therefore, the applicant is attempting to develop an aseptic molding device that completes sterilization of containers only by sterilization at the preform stage before the container is molded by aseptic blow molding, and for this reason, further improvements in sterilization efficiency are required.

[0006] Therefore, the present invention is intended to solve these problems, and has an object to provide an aseptic molding apparatus that is simply configured and capable of achieving a high sterilization treatment effect. [Means for solving the problem]

[0007] The aseptic molding apparatus of the present invention is an aseptic molding apparatus that aseptically molds sterilized containers that have been subjected to a sterilization treatment, and is equipped with a blow molding turret, an oven mechanism that performs a temperature increase treatment on preforms in an oven area set upstream of the blow molding turret, a preform conveying mechanism, and a sterilization treatment mechanism. The sterilization treatment mechanism is configured to complete sterilization of the containers only by sterilization treatment at the preform stage before the containers are molded by aseptic blow molding. The oven area is provided with a temperature increase area in which a temperature increase heater that increases the temperature of the preforms is installed, and an in-oven sterilization area that is adjacent to the downstream side of the temperature increase area in which the last temperature increase heater on the conveying path is installed and in which the preforms are sterilized by the sterilization treatment mechanism. The preform conveying mechanism is configured to convey the preforms through the temperature increase area and the in-oven sterilization area while maintaining the same preform held by the same holder, thereby solving the above problem. The above-mentioned aseptic molding apparatus may be configured such that the heating heater is not installed in the sterilization area of ​​the oven, and the sterilization processing mechanism performs a sterilization process in the sterilization area of ​​the oven on a preform that has been heated to the molding temperature for aseptic blow molding by the heating heater installed in the heating area. In any of the above aseptic molding apparatuses, a light irradiator that performs a sterilization treatment on the preforms by irradiating them with light may be installed in the sterilization area within the oven. In any of the above-mentioned aseptic molding apparatuses, the oven mechanism may include a sterilization chamber that defines a sterilization area within the oven, and the sterilization chamber may have an upstream opening that communicates with the temperature rising area and a downstream opening that communicates with a transfer area downstream of the oven area. In any of the above aseptic molding apparatus, the air pressure in the transfer area may be maintained at a higher pressure than the air pressure in the sterilization chamber. In any of the above-mentioned aseptic molding apparatuses, the air pressure in the sterilization chamber may be maintained at a higher pressure than the air pressure in the heating area. Any of the above aseptic molding apparatuses may be provided with a sterilizing agent supply device in the sterilizing area within the oven, which supplies a sterilizing agent to the preforms. In any of the above-mentioned aseptic molding apparatuses, an air jet that introduces non-sterilized air and jets it toward the mouth of the preform is installed in the heating area, and the air jet does not have to be installed in the oven sterilization area. In any of the above aseptic molding devices, the sterilization treatment mechanism may be configured to perform a sterilization treatment on an outer surface and an inner surface of a preform in the sterilization area inside the oven. Any of the above aseptic molding apparatuses may be provided with a heater in the sterilization area within the oven. Any of the above-mentioned aseptic molding apparatuses may be provided with an exhaust port for discharging air downstream, upstream, or directly above the upstream opening of the sterilization chamber. In any of the above-mentioned aseptic molding apparatuses, the sterilization area inside the oven may be provided with an inlet for supplying sterile air into the sterilization area inside the oven. Effect of the Invention

[0008] According to the present invention, a high sterilization effect can be obtained with a simple configuration. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is an explanatory diagram showing an aseptic filling system including an aseptic molding apparatus according to one embodiment of the present invention. [Diagram 2] FIG. 2 is an explanatory diagram showing the configuration of the aseptic molding apparatus, focusing on the oven area. [Diagram 3] FIG. 4 is an explanatory diagram showing the sterilization mode in the sterilization area inside the oven. [Figure 4] FIG. 4 is an explanatory diagram showing test conditions and test results in a test example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, a sterile filling system 10 according to one embodiment of the present invention will be described with reference to the drawings. The terms "upstream" and "downstream" used in this specification refer to the upstream and downstream in the conveying direction of the preform P or the container.

[0011] First, the aseptic filling system 10 is configured as a so-called in-line blow type filling system that aseptically fills sterilized containers with sterilized contents (particularly liquid contents), and as shown in Figure 1, it includes an aseptic molding device 20 that aseptically molds containers, and a filling device 60 that aseptically fills the containers with the contents.

[0012] Below, each component of the aseptic filling system 10 will be described with reference to the drawings.

[0013] First, the aseptic molding apparatus 20 aseptically molds sterilized containers that have been subjected to a sterilization treatment, and as shown in Figures 1 and 2, is equipped with an inlet section 21 for feeding the preform P, a blow molding turret 22, an oven mechanism 30 that subjects the preform P to a temperature increase treatment in an oven area A1 set downstream of the inlet section 21, a preform transport mechanism 40 that transports the preform P, and a sterilization treatment mechanism 50 that subjects the preform P to a sterilization treatment.

[0014] As shown in FIG. 1, the inlet portion 21 is a portion for introducing the preform P into the aseptic molding apparatus 20 (aseptic filling system 10).

[0015] The blow molding turret 22, as shown in FIG. 1, is disposed downstream of the oven area A1 and performs aseptic blow molding on the preforms P. Specifically, the blow molding turret 22 is configured as a turret equipped with a blow machine (not shown) that performs biaxial stretch blow molding of containers such as PET bottles by blowing sterile air into a preform P that has been heated to the molding temperature during aseptic blow molding.

[0016] The molding area A5 in which the blow molding turret 22 is installed is covered by a chamber, and a sterile atmosphere and positive pressure are maintained by blowing sterile air that has passed through a HEPA filter from above using an FFU (Fan Filter Unit). In addition, the blow molding turret 22, blow machine, and other equipment installed in the molding area A5 are sterilized up to the ends of the blow piping. Preforms P, which have been sterilized only at the preform stage, are transported to molding area A5 and aseptically blow molded. As a result, aseptic blow molding is performed in a sterile environment in molding area A5, which means that it is not necessary to locally create an atmosphere of sterile air or sterilizing gas near the transport path when transporting preforms P or bottles after blow molding in molding area A5, and it is also not necessary to sterilize the bottles after blow molding.

[0017] The oven mechanism 30 performs a heating process to raise the temperature of the preform P to the molding temperature during aseptic blow molding in the blow molding turret 22, and as shown in Figures 1 and 2, is equipped with an oven chamber 31 having an oven area A1 inside, a sterilization chamber 32 provided within the oven chamber 31, a plurality of temperature-raising heaters 33 installed in a temperature-raising area A2 within the oven area A1, a heat retention heater 34 installed in an in-oven sterilization area A3 within the oven area A1, and a plurality of air ejectors (not shown) installed in the temperature-raising area A2. In addition, the oven mechanism 30 may be provided with a simple cover surrounding the periphery of the oven instead of the oven chamber 31, and the oven chamber 31 may not be provided.

[0018] As shown in Figures 1 and 2, the oven chamber 31 covers the oven area A1 and separates the oven area A1 from the outside, and has an entrance opening for loading the preform P and an exit opening for unloading the preform P.

[0019] As shown in Figures 1 and 2, within the oven chamber 31 (oven area A1), there is a temperature-raising area A2 in which a temperature-raising heater 33 is installed to raise the temperature of the preform P, and an in-oven sterilization area A3 adjacent to the downstream side of the temperature-raising area A2, in which the preform P is sterilized by a sterilization treatment mechanism 50.

[0020] As shown in Figs. 1 and 2, the sterilization chamber 32 is provided in the oven area A1 (in the oven chamber 31 in this embodiment), and defines an in-oven sterilization area A3. By providing this sterilization chamber 32, the oven area A1 is divided into an in-oven sterilization area A3 and a temperature rising area A2, and air in the temperature rising area A2 is prevented from entering the in-oven sterilization area A3. The sterilization chamber 32 has an upstream opening communicating with the temperature raising area A2, and a downstream opening communicating with the transfer area A4 downstream of the oven area A1. The upstream and downstream openings of the sterilization chamber 32 are designed to be as small as possible to allow the preforms P and the holders 41a (described later) to pass through, in order to suppress air flow between the in-oven sterilization area A3 and the heating area A2, and between the in-oven sterilization area A3 and the transfer area A4.

[0021] The heating heater 33 is configured as an infrared heater and, as shown in FIG. 2, is installed in the heating area A2 to the side of the transport route R of the preform P (specifically, on the outer periphery of the transport route R by the transport machine 41 described later) and heats mainly the body portion P1 of the preform P to raise the temperature of the body portion P1 to the molding temperature (approximately 120°C) during aseptic blow molding.

[0022] The body portion P1 of the preform P is a portion that is placed inside the mold during aseptic blow molding and is expanded within the mold, while the mouth portion P2 of the preform P is a portion that is placed outside the mold during aseptic blow molding and is not expanded.

[0023] The last heating heater 33 placed on the transport path of the preform P (i.e., near the transport route R) is installed within the heating area A2, as shown in Figure 2. In other words, no heating heater configured to heat the preform P is installed downstream of the heating area A2 (in-oven sterilization area A3 or transfer area A4). As a result, the preform P is sterilized in the sterilization area A3 in the oven in a high-temperature state after the temperature has been raised to the molding temperature, making it possible to satisfactorily sterilize the bacteria on the surface of the body part P1 of the preform P. In particular, when sterilization is performed by light irradiation, most of the mold that is weak to heat and resistant to UV light is sterilized in advance by raising the temperature, so the output of the light irradiator 51 required to keep the number of attached mold and spore-forming bacteria below a certain value can be kept low.

[0024] The warming heater 34 is configured as an infrared heater, and is installed in the sterilization area A3 inside the oven as shown in FIG. 2 in order to prevent the temperature of the body portion P1 of the preform P from decreasing during the sterilization process. As shown in FIG. 2, the heat retention heater 34 is installed on the side of the transport route R of the preform P, specifically, on the opposite side of the transport route R of the preform P from the various sterilization processors (the light irradiator 51 and the sterilizing agent supplier 52 described below) (specifically, on the outer periphery of the transport route R by the transport machine 41). As a result, in this embodiment, the preforms P are subjected to a heat retention treatment by the heat retention heater 34 while being subjected to a sterilization treatment by various sterilization treatment devices (light irradiator 51, sterilizing agent supply device 52).

[0025] Here, the degree of heating of the preform P by the heat retention heater 34 is set so that the temperature of the preform P (particularly the body portion P1 of the preform P) heated to the molding temperature is maintained within the molding temperature range (more preferably so that the temperature of the preform P does not rise), and is preferably set so that the temperature of the body portion P1 of the heated preform P is maintained at 100°C or higher (and 130°C or lower). In this way, the temperature of the body P1 of the preform P is maintained at 100°C or higher by heating with the heater 34, thereby preventing a temperature drop during transportation. Therefore, when sterilization is performed by light irradiation, UV light can be irradiated while maintaining the molding temperature, and a higher sterilization effect can be obtained than with UV sterilization when the surface temperature is close to room temperature. Also, when sterilization is performed with a sterilizing agent, a temperature drop due to the spraying of the sterilizing agent can be prevented.

[0026] The air jets (not shown) introduce non-sterile air and jet it toward the mouth P2 of the preform P so as to prevent the temperature of the mouth P2 of the preform P from rising too much due to heating by the temperature-raising heater 33 and to prevent the mouth P2 of the preform P from being deformed by heat, and a plurality of air jets are installed in the temperature-raising area A2 along the conveyance path of the preform P. Instead of the air jets, a shielding plate may be installed to block the heat from the temperature-raising heater 33 and prevent the mouth P2 from being heated. Here, the air blower (not shown) introduces non-sterile air and blows it out in the temperature-raising area A2, so the temperature-raising area A2 becomes an area whose atmosphere is contaminated by bacteria and the like introduced by the air blower (not shown).Even if an air blower is not installed, the temperature-raising area A2 becomes a contaminated area because environmental sterilization before production is not performed.

[0027] Since the air ejector described above is not installed in the in-oven sterilization area A3, the atmosphere in the in-oven sterilization area A3 is less contaminated than the atmosphere in the temperature rising area A2. In addition, since the in-oven sterilization area A3 is provided in direct communication with the temperature rising area A2, the atmosphere in the in-oven sterilization area A3 is more contaminated than the atmosphere in the transfer area A4 downstream of the in-oven sterilization area A3. In other words, the transfer area A4 is in a cleaner state than the in-oven sterilization area A3.

[0028] Here, as shown in Figures 1 and 2, the transfer area A4 is the area downstream of the oven sterilization area A3, is covered by a chamber, and is kept at a sterile atmosphere and positive pressure by blowing in sterile air that has passed through a HEPA filter from above using the FFU.

[0029] In addition, as shown in FIG. 2, the in-oven sterilization area A3 is provided with an inlet 35 for supplying sterile air from the FFU that sends out sterile air that has passed through a HEPA filter into the sterilization chamber 32 (in-oven sterilization area A3). Furthermore, an exhaust port 36 for exhausting air may be provided at one or more locations downstream, upstream, or directly above the upstream opening of the sterilization chamber 32 . Specifically, in the oven sterilization area A3, as shown in FIG. 2, an exhaust outlet 36 for exhausting air in the oven sterilization area A3 to the outside of the sterilization chamber 32 (oven chamber 31) may be provided at a position near the upstream opening of the sterilization chamber 32, upstream of the inlet 35 and downstream of the upstream opening of the sterilization chamber 32. In addition, the exhaust outlet 36 may be provided in a position near the upstream opening of the sterilization chamber 32, downstream within the temperature rising area A2 and upstream of the upstream opening of the sterilization chamber 32, or directly above the upstream opening of the sterilization chamber 32, so that air that has flowed out (or is about to flow out) from the sterilization area A3 in the oven to the temperature rising area A2 is exhausted to the outside of the temperature rising area A2. This controls the air pressure in the in-oven sterilization area A3 (sterilization chamber 32) and creates an air flow from downstream to upstream in the in-oven sterilization area A3 (sterilization chamber 32), preventing contaminated air in the in-oven sterilization area A3 from entering the transfer area A4. In addition, the exhaust port 36 prevents the sterilant gas in the in-oven sterilization area A3 from spreading into the temperature rise area A2. Furthermore, an area for collecting the sterilant gas may be provided between the in-oven sterilization area A3 and the temperature rise area A2.

[0030] The air pressure in the in-oven sterilization area A3 (sterilization chamber 32) is maintained lower than the air pressure in the transfer area A4. This prevents air in the in-oven sterilization area A3 from entering the transfer area A4, and also prevents contaminated air in the temperature-raising area A2 from entering the in-oven sterilization area A3 by forming an air flow from the transfer area A4 toward the in-oven sterilization area A3.

[0031] In addition, the air pressure in the oven sterilization area A3 (sterilization chamber 32) is maintained at a higher pressure than the air pressure in the temperature rising area A2, thereby preventing contaminated air from the temperature rising area A2 from entering the oven sterilization area A3.

[0032] In this embodiment, as shown in Fig. 1 and Fig. 2, the transfer area A4 has a first area A4-1 adjacent to the downstream side of the in-oven sterilization area A3, and a second area 4-2 adjacent to the downstream side of the first area A4-1, and the air pressure in the second area 4-2 is maintained higher than the air pressure in the first area A4-1. This creates an air flow from the downstream side to the upstream side in the transfer area A4, and more reliably prevents contaminated air in the in-oven sterilization area A3 from entering the transfer area A4. The transfer area A4 may be one area without being divided into the first area A4-1 and the second area 4-2.

[0033] As shown in FIG. 2, the transfer area A4 is provided with an inlet 23 for supplying sterile air from the FFU into the transfer area A4. As shown in FIG. 2, the transfer area A4 is provided with an exhaust port 24 on the upstream side of the inlet 23 for exhausting the air within the transfer area A4 to the outside (outside the chamber). This controls the air pressure within the transfer area A4, creating an air flow from downstream to upstream within the transfer area A4, and prevents contaminated air from the in-oven sterilization area A3 from entering the transfer area A4. The inlet 23 and the outlet 24 may be provided in the first area A4-1 and / or the second area A4-2 so that the air pressure in each area can be controlled individually. In addition, when sterilization using a sterilant is performed in the second area A4-2, an exhaust outlet 24 may be provided upstream, downstream, or directly above the opening between the first area A4-1 and the second area A4-2 to prevent the sterilant gas from spreading into the first area A4-1.

[0034] The preform conveying mechanism 40 conveys the preforms P inserted from the entrance 21 to the blow molding turret 22, and as shown in Figures 1 and 2, is equipped with a conveying machine 41 that conveys the preforms P mainly in the oven area A1, and multiple turrets 42 that convey the preforms P removed from the oven area A1 toward the blow molding turret 22.

[0035] As shown in Figures 2 and 3, the conveyor 41 is configured to convey the preform P through the heating area A2 and the oven sterilization area A3 while maintaining the same preform P held by the same holder 41a (in this embodiment, a mandrel inserted into the preform P), and in this embodiment, the holder 41a is configured to travel in a circular motion using a turret.

[0036] The conveyor 41 is configured to hold the preform P in an upright state (as shown in FIG. 3, an upward facing state with the mouth portion P2 of the preform P facing upward) and convey the preform P while rotating it around its axis X. As a result, as shown in Figures 2 and 3, it is possible to apply heat treatment and sterilization treatment to the rotating preform P from the outer periphery using a temperature raising heater 33 and a heat retention heater 34 installed on the side of the transport route R and various sterilization treatment devices (light irradiator 51, sterilizing agent supplier 52) described later, so that the outer surface of the preform P can be evenly heated and sterilized.

[0037] As can be seen from Figures 1 and 2, in order to install the conveying machine 41, an opening will be provided in the oven chamber 31 to connect the heating area A2 and the transfer area A4. However, it is preferable to make this opening as small as possible in order to keep the air flow between the heating area A2 and the transfer area A4 low.

[0038] The turrets 42 transport the preforms P in the transfer area A4 and the molding area A5, and each turret 42 has a plurality of grippers (not shown) that grip the preforms P from the outer periphery. It is preferable that the grippers have their gripping parts sterilized by UV irradiation or a disinfectant.

[0039] The transport posture of the preform P by the preform transport mechanism 40 may be any posture, such as an upright state, an inverted state (i.e., a downward state in which the mouth portion P2 of the preform P faces downward), or a horizontal state (i.e., a horizontal state in which the mouth portion P2 of the preform P faces to the side).

[0040] The sterilization mechanism 50 performs sterilization processing so that the container is in a commercially sterile state (i.e., a state in which all microorganisms harmful to public health that may grow in the beverage under normal non-refrigerated storage and distribution conditions have been killed) when the contents are filled in the filling device 60.

[0041] In this embodiment, the sterilization mechanism 50 is configured to complete sterilization of the container only through sterilization at the preform stage before the container is molded by aseptic blow molding, without performing sterilization at the container stage after aseptic blow molding (without requiring sterilization at the container stage) (more specifically, in this embodiment, sterilization is completed by the time of transfer area A4, and the preform P after sterilization is completed is transported to molding area A5).In other words, the container is configured to be in a commercially sterile state only through sterilization at the preform stage.In other words, the sterilization effect of 5D or more is obtained for the bacteria to be sterilized (bacteria that can grow in the contents to be filled into the container, such as mold, spore-forming bacteria, etc.) only through sterilization at the preform stage (for the entire outer surface including the inner and outer surfaces of the preform P). The bactericidal effect (D) is expressed by the formula: bactericidal effect (D) = LOG((initial number of bacteria) / (number of surviving bacteria)). For example, if the number of bacteria is reduced from 100 to 10, then LOG(100 / 10) = 1D. In addition, if the content to be filled is a low-acid beverage, a bactericidal effect of 5 to 6 D or more against mold and spore-forming bacteria is required, and if the content to be filled is mineral water, green tea, etc., a bactericidal effect of 5 to 6 D or more against mold is required.

[0042] As shown in Figs. 2 and 3, the sterilization mechanism 50 includes a light irradiator 51 and a sterilizing agent supplier 52, which are installed in the sterilization area A3 inside the oven.

[0043] The light irradiator 51 is equipped with a UV lamp (including a UV-LED) or a xenon lamp (xenon arc lamp) that irradiates UV light as its light source, and performs a sterilization treatment on the preform P by irradiating it with light. In this embodiment, as shown in FIG. 3, the light irradiator 51 is installed so as to irradiate light onto (at least) the outer surface of the body portion P1 of the preform P.

[0044] In this way, when light irradiator 51 is used as the sterilization processor constituting sterilization mechanism 50, it is possible to sterilize spore-forming bacteria by light irradiation, so not only can the range of use of aseptic molding apparatus 20 be expanded to contents other than green tea and water, but also mold and yeast can be sterilized by light irradiation, so the amount of disinfectant required to suppress the number of mold and yeast attachments below a certain value can be reduced, thereby reducing the risk of disinfectant remaining in the molded container. In addition, the cumulative light amount of the disinfecting light can be reduced, resulting in reduced energy costs during production. The light irradiator 51 may be configured in a form other than a light irradiator, for example, as a supplier that sprays and supplies a sterilizing agent such as hydrogen peroxide or peracetic acid.

[0045] As shown in FIG. 3, the sterilizing agent supplying device 52 applies a sterilizing treatment to (at least) the outer surface of the mouth portion P2 of the preform P, and in this embodiment, it is configured as a sterilizing agent supplying device that sprays and supplies (applies) a sterilizing agent such as hydrogen peroxide or peracetic acid onto the outer surface of the mouth portion P2 of the preform P. The sterilizing agent supplier 52 may be configured in a form other than that of a sterilizing agent supplier, for example, as a light irradiator that performs a sterilization treatment by irradiating UV light or xenon light, or an irradiator that irradiates an electron beam (EB).

[0046] In this manner, the light irradiator 51 and the sterilizing agent supplier 52 are installed in the oven sterilization area A3 arranged adjacent to the downstream side of the temperature-raising area A2, and the sterilization processing mechanism 50 is configured to perform a sterilization process in the oven sterilization area A3 on the preform P which has been heated to the molding temperature (approximately 120°C) during aseptic blow molding by the heating heater 33 installed in the temperature-raising area A2.

[0047] In addition to the light irradiator 51 and sterilizing agent supplier 52 described above, the sterilization mechanism 50 is equipped with a sterilization processor 53 installed downstream of the in-oven sterilization area A3 (and upstream of the blow molding turret 22, in this embodiment, the transfer area A4), as shown in FIG. 2. In this embodiment, the sterilization processor 53 is configured as a sterilant supplier that sprays and supplies (applies) a sterilant such as hydrogen peroxide or peracetic acid onto the inner surface of the preform P (the inner surfaces of the body portion P1 and the mouth portion P2). Sterilization processor 53 may be configured in a form other than that of a sterilizing agent supplier, for example, as a light irradiator that performs sterilization treatment by irradiating UV light or xenon light, or an irradiator that irradiates electron beams (EB).

[0048] In this embodiment, the inner surface of the preform P is sterilized by the sterilization processor 53 downstream of the sterilization area A3 inside the oven, but the outer surface of the mouth portion P2 of the preform P may also be sterilized downstream of the sterilization area A3 inside the oven. Furthermore, when a sterilization treatment is performed on the outer surface of the mouth portion P2 of the preform P downstream of the in-oven sterilization area A3, the sterilization treatment of the outer surface of the mouth portion P2 downstream of the in-oven sterilization area A3 may be performed instead of the sterilization treatment of the outer surface of the mouth portion P2 in the in-oven sterilization area A3, or may be performed in addition to the sterilization treatment of the outer surface of the mouth portion P2 in the in-oven sterilization area A3. When sterilization of the outer surface of the mouth part P2 downstream of the oven sterilization area A3 is performed in addition to sterilization of the outer surface of the mouth part P2 in the oven sterilization area A3, it is possible to reduce the load of each process for the sterilization of the outer surface of the mouth part P2, which is more difficult to sterilize than other parts of the preform P (the outer and inner surfaces of the body part P1, and the inner surface of the mouth part P2), and therefore the configuration of the sterilizing agent supplier 52 in the oven sterilization area A3 can be simplified, and it is not necessary to secure a large space for the oven sterilization area A3. In addition, it is possible to adopt different sterilization means (application of a sterilizing agent, irradiation of light, etc.) for the sterilization of the outer surface of the mouth part P2 in the oven sterilization area A3 and the sterilization of the outer surface of the mouth part P2 downstream of the oven sterilization area A3, and therefore the sterilization effect can be further improved.

[0049] The filling device 60 is installed downstream of the aseptic molding device 20, and as shown in Figure 1, is equipped with a filling section 61 that aseptically fills the contents into the container, and a capping section 62 that is located downstream of the filling section 61 and attaches a sterilized cap to the mouth of the container.

[0050] Each step in the filling device 60 is carried out within a chamber the interior of which is maintained in a sterile condition. The sterile state of the container is also maintained in the section where the container is transported between the aseptic molding apparatus 20 and the filling apparatus 60; in other words, the sterile state of the container is maintained throughout the entire section from when the container is aseptically blow-molded by the blow molding turret 22 to when the contents are aseptically filled into the container in the filling section 61; in this embodiment, the entire section is covered by a chamber to maintain the sterile state of the container in this section.

[0051] Next, a test carried out to confirm the surface temperature of the preform P and the sterilization effect by light irradiation will be described with reference to FIG.

[0052] In this test, first, 5.8 × 10 spores of B. atrophaeus were placed on each of 10 measurement points T on the outer surface of the body P1 of the preform P. 2 cfu, mold fungus (A. niger spores) 3.7 × 10 2 After the cfu was attached, the preform was dried in a clean room to prepare an inoculated preform P. In this test, a preform P having a height of 92 mm, an outer diameter of the body P1 of 22 mm, and a weight of 19 g was used.

[0053] Next, as Experimental Example 1, 30 preforms P inoculated under the above conditions were subjected to a temperature increase treatment on the body part P1 of the preform P using an infrared heater so that the surface temperature of the outer surface of the body part P1 of the preform P was about 127°C. Immediately after the temperature increase treatment, the integrated illuminance on the body part P1 of the preform P was 200 mJ / cm 2The preform P was irradiated with UV light from a UV-LED for 5 seconds so that the number of surviving bacteria was about 100%. Thereafter, the preform P was cooled in a sterile environment, and the number of surviving bacteria at a measurement point T was measured by the following standard method. That is, the surface of the measurement point T after sterilization was wiped and collected in its entirety using the swab method, suspended in a sterile dilution solution, and the number of bacteria was counted by the membrane filter method on a standard agar medium for each dilution ratio. The medium was cultured at 30°C for one week, and the number of colonies that appeared according to the dilution ratio was counted to determine the number of surviving bacteria. The following UV light irradiation device was used. Irradiation device: 9 UV LEDs (manufactured by Nikkiso, wavelength 265 nm standard (minimum 260 nm, maximum 270 nm, full width at half maximum 13 nm)

[0054] In addition, as Comparative Example 1, for 30 preforms P inoculated under the above conditions, the body part P1 of the preform P was subjected to a temperature increase treatment using an infrared heater so that the surface temperature of the outer surface of the body part P1 of the preform P was about 127°C, and then, after waiting for 15 seconds, the integrated illuminance of the body part P1 of the preform P was increased to 200 mJ / cm 2 The preform P was irradiated with UV light from a UV-LED for 5 seconds so that the number of surviving bacteria was about 100%. Thereafter, the preform P was cooled in a sterile environment, and the number of surviving bacteria at the measurement point T was measured using the standard method under the above conditions.

[0055] In addition, as Comparative Example 2, 30 preforms P inoculated under the above conditions were subjected to a temperature increase treatment using an infrared heater under the above conditions, and the cumulative illuminance (cumulative light amount) at the body P1 of the preform P was 400 mJ / cm 2 The preform P was irradiated with UV light from a UV-LED for 5 seconds so that the number of surviving bacteria was about 100%. Thereafter, the preform P was cooled in a sterile environment, and the number of surviving bacteria at the measurement point T was measured using the standard method under the above conditions.

[0056] In addition, as Comparative Example 3, 30 preforms P inoculated under the above conditions were used, and the integrated illuminance at the body P1 of the preform P was 200 mJ / cm 2 (without performing the heating treatment using the infrared heater under the above conditions).2 The preform P was irradiated with UV light from a UV-LED for 5 seconds so that the number of surviving bacteria was about 100%. Thereafter, the preform P was cooled in a sterile environment, and the number of surviving bacteria at the measurement point T was measured using the standard method under the above conditions.

[0057] In addition, as Comparative Example 4, 30 inoculated preforms P under the above conditions were subjected to only the heating process using an infrared heater under the above conditions (and cooling in a sterile environment under the above conditions) (without irradiating them with UV light using a UV-LED under the above conditions), and the number of surviving bacteria at measurement point T was then measured using the standard method under the above conditions.

[0058] The above-mentioned accumulated illuminance (accumulated light amount) was adjusted using a UV scale (manufactured by Fujifilm). The method for calculating the amount of ultraviolet light using the UV scale is as follows: (UV scale used) Film manufacturer: Fujifilm Film type: UV scale L Applicable lamp type: Measured in low pressure mercury lamp mode Measurement light intensity range: 20-3000mJ / cm 2 Compatible wavelengths: 200nm-420nm (How to calculate the amount of ultraviolet light) The PET piece with the above UV scale (film) attached was irradiated with UV light using the UV lamp used in this test, and the amount of UV light was measured based on the color of the UV scale irradiated with the UV light. The amount of light measured at the measurement point was calculated by calculating the average integrated light amount within a 10 mm square of the UV scale centered on the measurement point (the average value of the amount of light measured in 0.125 mm squares per unit area).

[0059] The results of the above test are as follows:

[0060] First, in Example 1, neither spore-forming bacteria nor mold bacteria were detected at measurement point T, and it was confirmed that a bactericidal effect of 5.0D or more was obtained for both spore-forming bacteria and mold bacteria (calculated using the viable bacteria count measurement method).

[0061] In addition, in Comparative Example 1, it was confirmed that a bactericidal effect of 5.0D or more was obtained for mold bacteria, but a bactericidal effect of only about 3.3D was obtained for spore-forming bacteria.

[0062] In addition, in Comparative Example 2, it was confirmed that a bactericidal effect of 5.0D or more was obtained for spore-forming bacteria, but a bactericidal effect of only about 2.3D was obtained for mold bacteria.

[0063] Moreover, it was confirmed that in Comparative Example 3, only low bactericidal effects (2.6D, 0.8D) were obtained for both spore-forming bacteria and mold bacteria.

[0064] In addition, in Comparative Example 4, it was confirmed that a bactericidal effect of 5.0D or more was obtained for mold bacteria, but a bactericidal effect of only about 0.6D was obtained for spore-forming bacteria.

[0065] From the results of Example 1 and Comparative Examples 1 to 4 above, it was confirmed that when a sterilization treatment by light irradiation is performed immediately after the body portion P1 of the preform P is subjected to a heating treatment by an infrared heater, in other words, when the surface temperature of the preform P is high, the sterilization effect by light irradiation is further improved, and a high sterilization effect (5.0D or more) can be obtained for both spore-forming bacteria and mold bacteria.

[0066] In the aseptic filling system 10 of this embodiment obtained in this manner, by providing an oven sterilization area A3 adjacent to the downstream side of the heating area A2, it is possible to carry out the sterilization process while maintaining the temperature of the preform P heated in the heating area A2 high, thereby obtaining a high sterilization effect.

[0067] Furthermore, since the preform P is transported through the heating area A2 and the in-oven sterilization area A3 while being held by the same holder 41a without transferring the preform P between multiple holders, the preform P can be quickly moved to the in-oven sterilization area A3 while maintaining the temperature of the preform P heated in the heating area A2 high, and the heated portion of the preform P that has been subjected to heating treatment in the heating area A2 can be sterilized directly in the in-oven sterilization area A3, thereby achieving a high sterilization effect by the sterilization treatment in the in-oven sterilization area A3.

[0068] Furthermore, since there is no need to prepare equipment or space within the oven area A1 for transferring preforms P between multiple holders, the equipment environment within the oven area A1 can be kept simple, and the contamination level of the atmosphere in the oven sterilization area A3 in particular can be kept low.

[0069] Furthermore, by providing the in-oven sterilization area A3 within the oven area A1, it is not necessary to install sterilization equipment in the transfer area A4 downstream of the oven area A1, or it is possible to simplify the equipment configuration of the sterilizer 53 installed in the transfer area A4, making it easier to ensure hygiene in the transfer area A4.

[0070] Moreover, by sterilizing the preforms P immediately after they have been heated to the molding temperature during aseptic blow molding by the heating heater 33 installed in the heating area A2, a high sterilization effect can be obtained.

[0071] Furthermore, since a light irradiator 51 that performs a sterilization treatment on the preform P by irradiating it with light is installed in the sterilization area A3 inside the oven, it is possible to perform the sterilization treatment while maintaining the temperature of the preform P heated in the heating area A2 high, and therefore it is possible to obtain a high sterilization effect by taking advantage of the fact that the sterilization effect of light irradiation is improved when the surface temperature of the area to be sterilized is high.

[0072] Furthermore, by providing the sterilization chamber 32, it is possible to control the air flow within the oven area A1 and prevent the air within the temperature rising area A2 from entering the in-oven sterilization area A3, thereby preventing the in-oven sterilization area A3 from being contaminated by the air from the temperature rising area A2.

[0073] In addition, by providing an in-oven sterilization area A3 partitioned by a sterilization chamber 32 between the transfer area A4 and the temperature rising area A2, the in-oven sterilization area A3 can function as a buffer area that prevents the air in the temperature rising area A2 from being brought directly into the transfer area A4, thereby preventing the atmosphere in the transfer area A4 from being polluted by the air in the temperature rising area A2.

[0074] Furthermore, by installing a sterilizing agent supplier 52 configured as a sterilizing agent supplier that supplies a sterilizing agent to the preforms P in the oven sterilization area A3, not only can a high sterilization effect be obtained by carrying out a sterilization treatment using a sterilizing agent while maintaining the temperature of the preforms P heated in the heating area A2 high, but also, by making the atmosphere in the oven sterilization area A3 a sterilizing agent atmosphere, it is possible to reduce the contamination level of the atmosphere in the oven sterilization area A3, so that the oven sterilization area A3 can function effectively as a buffer region for the atmospheric contamination level, and it is possible to prevent the atmosphere in the transfer area A4 from being contaminated by the air in the heating area A2.

[0075] In addition, by installing an air jet (not shown) that jets air toward the mouth P2 of the preform P in the heating area A2, the temperature of the mouth P2 of the preform P can be prevented from increasing due to heating by the heating heater 33, and by not installing the air jet in the oven sterilization area A3, contamination of the oven sterilization area A3 due to the air jetted from the air jet can be avoided.

[0076] Furthermore, by installing a heat retention heater 34 in the oven sterilization area A3, not only can a drop in temperature of the preforms P due to the sterilization process in the oven sterilization area A3 be prevented and the temperature of the preforms P can be maintained high, but also the room temperatures in the oven sterilization area A3 and the heating area A2 can be maintained high.

[0077] Furthermore, when the heat retention heater 34 and the light irradiator 51 are installed in the oven sterilization area A3 as in this embodiment, mold on the outer surface of the preform P can be sterilized by the heat of the heat retention heater 34, while spore-forming bacteria on the outer surface of the preform P can be sterilized by light irradiation by the light irradiator 51.

[0078] Furthermore, when the sterilization agent supplying device 52 configured as a heat retention heater 34 and a sterilization agent supplying device is installed in the sterilization area A3 inside the oven as in this embodiment, it is possible to suppress the temperature drop of the preform P caused by the application of the sterilization agent, so that the sterilization effect of the sterilization agent can be obtained satisfactorily.

[0079] Although the embodiments of the present invention have been described above in detail, the present invention is not limited to the above-mentioned embodiments, and various design modifications can be made without departing from the scope of the present invention described in the claims. In addition, the configurations of the above-mentioned embodiments and the modified examples described below may be arbitrarily combined to configure the aseptic filling system 10 (aseptic molding device 20).

[0080] For example, in the above-described embodiment, the in-oven sterilization area A3 has been described as being the area set at the most downstream position within the oven area A1, but other areas may be provided downstream of the in-oven sterilization area A3 within the oven area A1.

[0081] Furthermore, the specific embodiment of the sterilization mechanism 50 is not limited to the above, and any mechanism may be used as long as it performs sterilization at least in the in-oven sterilization area A3. For example, in the above-described embodiment, the light irradiator 51 and the sterilizing agent supplier 52 are described as being installed in the oven sterilization area A3, but only one of the light irradiator 51 or the sterilizing agent supplier 52 may be installed in the oven sterilization area A3.

[0082] In addition, in the above-described embodiment, the light irradiator 51 is installed in the oven sterilization area A3 as a sterilization processor that sterilizes the outer surface of the body portion P1 of the preform P. However, a sterilizer supplier that supplies a sterilizer to the outer surface of the body portion P1 of the preform P may also be installed in the oven sterilization area A3 as a sterilization processor that sterilizes the outer surface of the body portion P1 of the preform P.

[0083] In the above embodiment, the sterilization treatment of the inner surface of the preform P is performed downstream of the oven sterilization area A3, but the sterilization treatment may be performed in the oven sterilization area A3. In this case, the specific form of the sterilization treatment device that performs the sterilization treatment on the inner surface of the preform P in the oven sterilization area A3 may be any, but as an example, a flow path for passing a sterilizing agent may be formed in the above-mentioned holding tool (mandrel) 41a, and the sterilizing agent may be supplied to the inner surface of the preform P in a state held by the holding tool 41a through the above-mentioned flow path. As an example, a light irradiator may be installed at the tip of the above-mentioned holding tool (mandrel) 41a, and the inner surface of the preform P in a state held by the holding tool 41a may be sterilized by light irradiation. If the inner surface of the preform P is sterilized in the oven sterilization area A3 instead of the transfer area A4, the preform P will be annealed in the transfer area A4 which is maintained in a sterile state.

[0084] In addition, for areas other than the oven sterilization area A3 (areas downstream of the oven area A1 and areas upstream of the oven area A1), any sterilization treatment device may be installed, such as a sterilization treatment device that applies sterilization treatment to the inner surface of the preform P in the area upstream of the oven area A1, or no sterilization treatment device may be installed. In addition, the specific embodiment of the sterilization processor to be installed in an area other than the sterilization area A3 in the oven may be any type, such as one that performs sterilization processing by using light irradiation or one that performs sterilization processing by supplying a sterilizing agent, and the sterilization points of the preform P by the sterilization processor may also be set as desired.

[0085] In addition, various processing devices other than those described above may be installed as components of the sterilization processing mechanism 50, such as a hot water supplier that supplies hot water to the preform P, a dust remover that removes dust adhering to the preform P, an irradiator that irradiates the preform P with an electron beam (EB), and a steam ejector that sprays water vapor (or superheated steam) onto the preform P.

[0086] Furthermore, the locations of sterilization in the preform P using the various processors (the above-mentioned light irradiator, sterilization processor, and sterilant supplier) may be determined arbitrarily depending on the embodiment. For example, in the above-mentioned embodiment, the light irradiator 51 is described as performing sterilization treatment on the outer surface of the body P1 of the preform P, but the light irradiator 51 may be set to perform sterilization treatment on locations other than the outer surface of the body P1.

[0087] In addition, the sterilization mechanism 50 may be configured to perform sterilization on the outer and inner surfaces of the preform P in the oven sterilization area A3. In this case, it is not necessary to install sterilization equipment in the transfer area A4 downstream of the oven area A1, or it is possible to simplify the configuration of the sterilization equipment installed in the transfer area A4, making it easier to ensure the hygiene of the transfer area A4.

[0088] Furthermore, in the above-described embodiment, the warming heater 34 is described as being installed in the in-oven sterilization area A3, but the warming heater 34 does not have to be installed in the in-oven sterilization area A3, and the warming heater 34 may be installed in an area downstream of the in-oven sterilization area A3 (such as the transfer area A4) (instead of the warming heater 34 in the in-oven sterilization area A3, or in addition to the warming heater 34 in the in-oven sterilization area A3). [Explanation of symbols]

[0089] 10. Aseptic filling system 20... Aseptic molding equipment 21 Entrance 22 Blow Molding Turret 23 Introduction 24... Outlet 30 Oven mechanism 31 Oven chamber 32 Sterilization chamber 33 Heating heater 34 Heater 35 ··· Entry point 36... Outlet 40 Preform transport mechanism 41 ...Conveyor 41a... Holder 42 Turret 50 Sterilization mechanism 51 ... light irradiator 52 Disinfectant dispenser 53 Sterilization equipment 60... Filling equipment 61 Filling section 62 Capping section P ··· Preform P1: Body of the preform P2: Mouth of preform A1 Oven area A2: Heating area A3: Oven sterilization area A4...Transfer Area A4-1 Area 1 A4-2: Area 2 A5: Molding area R Preform transport route

Claims

1. An aseptic molding apparatus for aseptically molding a sterilized container that has been subjected to a sterilization treatment, The apparatus includes a blow molding turret, an oven mechanism for heating the preform in an oven area set upstream of the blow molding turret, a preform transport mechanism, and a sterilization mechanism, The sterilization mechanism is configured to complete sterilization of the container only by sterilization at the preform stage before the container is molded by aseptic blow molding, Within the oven area, a heating area in which a heating heater for heating the preform is installed, and an oven sterilization area adjacent to the downstream side of the heating area in which the last heating heater on the conveying path is installed and in which the sterilization treatment is performed on the preform by the sterilization treatment mechanism are provided; The aseptic molding apparatus is characterized in that the preform transport mechanism is configured to transport the preform through the heating area and the oven sterilization area while maintaining the same preform held by the same holder.

2. The heating heater is not installed in the sterilization area in the oven, 2. The aseptic molding apparatus according to claim 1, wherein the sterilization mechanism is configured to sterilize in the sterilization area of ​​the oven a preform whose temperature has been raised to a molding temperature for aseptic blow molding by the heating heater installed in the heating area.

3. 2. The aseptic molding apparatus according to claim 1, wherein a light irradiator that sterilizes the preforms by irradiating them with light is installed in the sterilization area inside the oven.

4. The oven mechanism includes a sterilization chamber that defines a sterilization area within the oven, 2. The aseptic molding apparatus according to claim 1, wherein the sterilization chamber has an upstream opening communicating with the heating area and a downstream opening communicating with a transfer area downstream of the oven area.

5. 5. The aseptic molding apparatus of claim 4, wherein the air pressure in the transfer area is maintained at a higher pressure than the air pressure in the sterilization chamber.

6. 6. The aseptic molding apparatus according to claim 5, wherein the air pressure in the sterilization chamber is maintained higher than the air pressure in the heating area.

7. 5. The aseptic molding apparatus according to claim 4, wherein a sterilizing agent supplying device for supplying a sterilizing agent to the preforms is installed in the sterilizing area in the oven.

8. An air blower is installed in the heating area to introduce non-sterile air and blow it toward the mouth of the preform, 5. The aseptic molding apparatus according to claim 4, wherein the air blower is not installed in the sterilization area in the oven.

9. 2. The aseptic molding apparatus according to claim 1, wherein the sterilization mechanism is configured to perform a sterilization treatment on an outer surface and an inner surface of a preform in the sterilization area inside the oven.

10. 3. The aseptic molding apparatus according to claim 2, wherein a heater is provided in the sterilization area of ​​the oven.

11. 5. The aseptic molding apparatus according to claim 4, wherein an exhaust port for exhausting air is provided downstream, upstream, or directly above the upstream opening of the sterilization chamber.

12. 2. The aseptic molding apparatus according to claim 1, wherein the sterilization area in the oven is provided with an inlet for supplying sterile air into the sterilization area in the oven.

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