Filling system and filling method

Abstract

To address a worker shortage by reducing the number of workers engaged in a blending task during non-blending periods.SOLUTION: A filling system 100 fills a container with a beverage produced by mixing a concentrate with a diluent during a blending period in which the concentrate is blended from ingredients and during a non-blend period in which blending of the concentrate is stopped, and the system includes: a blending unit 10 that blends the concentrate; a sterilization unit 20 that sterilizes the concentrate supplied from the blending unit; at least one first storage tank 30A that stores the sterilized concentrate supplied during the blending period; at least one second storage tank 30C for storing the sterilized concentrate that is supplied during non-blending periods; a mixing unit 40 for mixing a diluent with the concentrate supplied from the first storage tank or the second storage tank in a sterile environment to produce a beverage; and a filling unit 50 for filling a container with the produced beverage.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a filling system and a filling method for storing a stock solution supplied during a non-coordination time zone.

Background Art

[0002] Patent Document 1 describes an aseptic filling system including a tank for holding a filling liquid and a filling machine to which the filling liquid is supplied from the tank. As this filling liquid, tea-based beverages or the like are used, and a filling liquid pipe for introducing the filling liquid into the tank is provided.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a filling system for filling beverages such as soft drinks into containers, operations by a plurality of operators are required for the management and operation of the filling system. In recent years, there has been a problem of a shortage of workers engaged in operations as operators. In order to address such a shortage of workers, it is conceivable to review the coordinated operations on a 24-hour basis and provide a non-coordination time zone at night or the like. As a result, the number of workers engaged in coordinated operations during the non-coordination time zone can be reduced, and the shortage of workers can be dealt with. However, if the filling of beverages is stopped during the non-coordination time zone, the quantity of products produced will decrease. Therefore, a filling system that continues to fill beverages during the non-coordination time zone is required.

Means for Solving the Problems

[0005] A filling system according to one aspect is a filling system for filling a container with a beverage produced by mixing a diluent into a stock solution during a preparation time period for preparing the stock solution from raw materials and a non-preparation time period for stopping the preparation of the stock solution, wherein: a preparation unit for preparing the stock solution; a sterilization unit for sterilizing the stock solution supplied from the preparation unit; at least one first storage tank for storing the sterilized stock solution supplied during the preparation time period; at least one second storage tank for storing the sterilized stock solution supplied during the non-preparation time period; a mixing unit for producing the beverage by mixing the diluent into the stock solution supplied from the first storage tank or the second storage tank in a sterile environment; and a filling unit for filling the produced beverage into the container.

[0006] Also, a filling method according to another aspect is a filling method for filling a container with a beverage produced by mixing a diluent into a stock solution during a preparation time period for preparing the stock solution from raw materials and a non-preparation time period for stopping the preparation of the stock solution, the method comprising: preparing the stock solution in a preparation unit; sterilizing the stock solution supplied from the preparation unit; storing the sterilized stock solution supplied during the preparation time period in at least one first storage tank; storing the sterilized stock solution supplied during the non-preparation time period in at least one second storage tank; producing the beverage by mixing the diluent into the stock solution supplied from the first storage tank or the second storage tank in a mixing unit in a sterile environment; and filling the produced beverage into the container.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Mode for Carrying Out the Invention

[0008] Hereinafter, exemplary embodiments for carrying out the present invention will be described in detail with reference to the drawings. However, the dimensions, materials, shapes, and relative positions of the components described in the following embodiments can be arbitrarily set and can be changed according to the configuration or various conditions of the apparatus or method to which the present invention is applied. Also, unless otherwise specified, the scope of the present invention is not limited to the embodiments specifically described below.

Examples

[0009] [First Embodiment] First, with reference to FIG. 1, the filling system 100 will be described. Note that each device and each tank explicitly shown as components of the filling system 100, and other devices (for example, metering devices, etc.) included in the filling system 100 are connected by a supply path for liquids and the like. This supply path is, as an example, a supply pipe, but may also be a path supplied by an operator or a conveying device. Also, each device, each tank, and other devices may be one or a plurality. Furthermore, each device, each tank, and other devices may function independently or may be a unit that functions together with other machines or structures, etc.

[0010] In the filling system 100, the beverage is filled into the container both during the mixing time period for preparing the stock solution from the raw materials and during the non-mixing time period when the mixing of the stock solution is stopped. This beverage is manufactured by mixing a diluent with the stock solution obtained by mixing. Examples of beverages include tea-based beverages, coffee beverages, carbonated beverages, fruit beverages, vegetable beverages, sports beverages, lactic acid bacteria beverages, dairy products, and alcoholic beverages, etc. Also, examples of diluents include pure water, natural water, mineral water, and carbonated water, etc. Hereinafter, an example where the beverage is a tea-based beverage and the diluent is pure water will be mainly described.

[0011] The filling system 100 includes an extraction device 61 that extracts tea, which is part of the raw material for beverages. This extraction device 61 extracts tea using tea leaves and an extraction solvent such as heated water. As an example, the extraction device 61 is a kneader-type extractor or a column-type extractor. Further, the filling system 100 may include, as part of the extraction device 61 or separately from the extraction device 61, a tank for storing the extraction solvent, a tank for storing the extraction solvent before heating, a generation device for the extraction solvent, a hopper for supplying tea leaves, and a cooler for tea, etc. In the following description, the extracted extraction solvent is also referred to as the main raw material.

[0012] Also, the filling system 100 includes a separation device 62 that separates a part of the components of the extracted tea. As an example, the separation device 62 is a centrifuge or a filter-type separator having a separation filter. Further, the filling system 100 may include a generation device for generating a removal liquid that removes caffeine, etc. from the tea as the liquid supplied to the separation device 62. Also, the filling system 100 may include, as part of the separation device 62 or separately from the separation device 62, a removal liquid tank for storing the removal liquid, etc.

[0013] Furthermore, the filling system 100 includes a main raw material tank 63 for temporarily storing the main raw material. Also, the filling system 100 includes a sub-raw material tank 64 for temporarily storing sub-raw materials that are part of the raw materials. As an example, the sub-raw materials are isomerized sugar liquid sugar, granulated sugar liquid sugar, sterilized milk, dissolved milk powder, dissolved flavor, and other liquids or powders. Note that multiple types of sub-raw materials may be stored in one sub-raw material tank 64, or each sub-raw material may be stored in a dedicated sub-raw material tank 64.

[0014] And the filling system 100 includes a mixing tank 11 for preparing a stock solution from a main raw material and auxiliary raw materials which are the raw materials. The main raw material stored in the main raw material tank 63 and the auxiliary raw material stored in the auxiliary raw material tank 64 are supplied to this mixing tank 11. For example, in the mixing tank 11, the main raw material and the auxiliary raw materials are stirred to prepare a stock solution. As an example, the number of mixing tanks 11 is two, and each mixing tank 11 has a capacity capable of preparing 45,000 L or 45 tons of stock solution. However, the number of mixing tanks 11 may be one or three or more, and the capacity of the mixing tank 11 may be less than 45,000 L or more than 45,000 L.

[0015] Also, the filling system 100 includes a sterilization device 21 for sterilizing the stock solution supplied from the mixing tank 11. For example, the sterilization device 21 sterilizes by a method of heating, a method of irradiating ultraviolet rays, a method of filtering and sterilizing by passing through a filter, etc. As an example, the sterilization device 21 is a shell & tube type sterilization device. Note that the filling system 100 may include a buffer tank or the like for primarily storing the stock solution as a part of the sterilization device 21 or separately from the sterilization device 21.

[0016] Furthermore, as an example of a storage tank 30 for storing the sterilized stock solution, the filling system 100 includes a sterile tank for storing the stock solution in a sterile environment. Also, the filling system 100 includes a sterile blender 41 for manufacturing a beverage by mixing a diluent with the stock solution supplied from the storage tank 30 in a sterile environment. And the storage tank 30 includes at least one first storage tank for storing the stock solution supplied to the sterile blender 41 during the mixing time period. Also, the storage tank 30 includes at least one second storage tank for storing the stock solution supplied to the sterile blender 41 during the non-mixing time period.

[0017] As an example, the number of storage tanks 30 is four, and each storage tank 30 has a capacity to store 35,000 L or 35 tons of the stock solution. However, the number of storage tanks 30 may be three or less or five or more, and the capacity of the storage tank 30 may be less than 35,000 L or more than 35,000 L. Further, at least one of the plurality of storage tanks 30 may have a capacity different from that of the other storage tanks 30.

[0018] The blending time period and the non-blending time period are preset. For example, the blending time period is a time period including daytime (a time period from 7:00 to 22:30 as an example), and the non-blending time period is a time period including nighttime (a time period from 22:30 to 7:00 as an example). However, the blending time period may include nighttime, and the non-blending time period may include daytime. Also, various operations for blending, such as preparation operations for raw materials, etc., and cleanup operations such as washing are also performed during the blending time period.

[0019] Furthermore, the lengths of the blending time period and the non-blending time period may be the same or different. Also, the non-blending time period may be a time period of late-night work defined in the Labor Standards Act (for example, a time period from 22:00 to 5:00). In this case, the blending time period may be a time period excluding the time period of late-night work (for example, a time period from 5:00 to 22:00).

[0020] Furthermore, a plurality of non-blending time periods or a plurality of blending time periods may be set within one day (that is, 24 hours). For example, blending time periods and non-blending time periods of several hours each may be set alternately. Also, a time period during which filling operations are not performed may be set as a time period that does not belong to either the non-blending time period or the blending time period within one day. In this case, the total length of the non-blending time period and the blending time period is less than 24 hours. That is, both the non-blending time period and the blending time period are time periods during which filling of beverages is performed.

[0021] In addition, the filling system 100 may include a buffer tank or the like that primarily stores the stock solution, either as part of the aseptic blender 41 or separately from the aseptic blender 41. The buffer tank is a sterile tank in which the sterilized stock solution is stored. In this specification, a buffer tank that functions as a sterile tank may sometimes be simply referred to as a buffer tank.

[0022] Furthermore, the filling system 100 includes a diluent supply source 65 that supplies the aseptic diluent to the aseptic blender 41. As an example, the diluent supply source 65 supplies aseptic pure water as the diluent to the aseptic blender 41. In addition, the filling system 100 may include a diluent generation device, a device for sterilizing the diluent, and a buffer tank or the like that primarily stores the diluent, either as part of the diluent supply source 65 or separately from the diluent supply source 65.

[0023] The buffer tank that stores the diluent is a sterile tank in which the sterilized diluent is stored. The device for sterilizing the diluent sterilizes the diluent by methods such as heating, irradiating with ultraviolet light, and filtering and sterilizing by passing through a filter. Furthermore, the filling system 100 may include a tank or the like that stores a liquid such as water used for generating the diluent, either as part of the diluent supply source 65 or separately from the diluent supply source 65.

[0024] And the filling system 100 includes a filling device 51 that fills the manufactured beverage into a container. This filling device 51 fills the beverage into the container in a sterile environment. As an example, the containers include PET bottles, paper packs, cans, and bottles. Alternatively, the filling device 51 may include a device for sterilizing the beverage in the container filled with the beverage. For example, the device sterilizes the beverage by irradiating it with ultraviolet light.

[0025] Furthermore, the filling system 100 includes a control device 70. This control device 70 controls the entire filling system 100 or at least one of each device and each part of the filling system 100. For example, the control device 70 is configured as a computer that combines a processor that executes various arithmetic processes and operation controls according to a predetermined program and other peripheral devices.

[0026] As an example, the control device 70 has a processor and a memory as a storage unit that stores a control program. The processor is, for example, a CPU (Central Processing Unit) or an MPU (Micro-Processing Unit), and based on the program stored in the memory, controls the entire system and also comprehensively controls various processes. Note that the control device 70 may have an integrated circuit such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array).

[0027] The memory includes a RAM (Random Access Memory) that is a system work memory for the operation of the processor, and storage devices such as a ROM (Read Only Memory), an HDD (Hard Disc Drive), and an SSD (Solid State Drive) that store programs and system software.

[0028] In addition, an operating device including a keyboard or various switches for inputting predetermined commands and data is connected to the control device 70 by wire or wirelessly. Further, a display device for displaying the input state, setting state, measurement results, and various information of the device is connected to the control device 70 by wire or wirelessly. Furthermore, the control device 70 can also perform control according to a program stored in a portable recording medium such as a CD (Compact Disc), DVD (Digital Versatile Disc), CF (Compact Flash) card, and USB (Universal Serial Bus) memory, or an external storage medium such as a server on the Internet.

[0029] For example, the control device 70 acquires or calculates a target storage amount according to the total filling amount of the beverage in the non-blending time zone. Then, the control device 70 causes the display device to display the target storage amount. For example, the total filling amount is calculated by multiplying the number of filling times scheduled in the non-blending time zone by the capacity of each container. However, the target storage amount may be more than the total filling amount. As an example, the control device 70 causes the display device arranged close to the storage tank 30 to display the target storage amount. When acquiring the target storage amount, the control device 70 acquires the target storage amount input by the operator or the target storage amount stored in an external storage device. Furthermore, the control device 70 may acquire the target storage amount calculated by an external device.

[0030] The display device may be provided integrally with the control device 70, or each device or each part of the filling system 100. Further, the display device may be connected to at least one of each device and each part of the filling system 100 by wire or wirelessly. As another example, when the amount of the stock solution stored in the storage tank 30 reaches the target storage amount, the control device 70 may cause the display device arranged close to the storage tank 30 to display that the target storage amount has been reached.

[0031] Further, when the storage amount of any one of the storage tanks 30 reaches the capacity, the control device 70 may switch the supply path so that the stock solution is sent to another storage tank 30. As yet another example, the control device 70 may control the on-off valves provided in each device or each part of the filling system 100 or in the supply pipes. As an example, when the total amount of the stock solution stored in the plurality of storage tanks 30 reaches the target storage amount, the control device 70 closes the on-off valve of the supply pipe between the blending tank 11 and each storage tank 30.

[0032] Furthermore, the control device 70 may calculate the target storage amount so as to include the amount of the stock solution remaining in the supply pipe after blending. For example, the control device 70 calculates the target storage amount so as to include the amount of the stock solution remaining in the supply pipe between the sterilization device 21 and the storage tank 30. Also, the control device 70 may calculate the target storage amount so as to include the amount of the stock solution remaining in the buffer tank after blending. In these cases, the target storage amount will be more than the total filling amount of the beverage.

[0033] [Filling Method] Subsequently, with reference to FIGS. 2 and 3, the filling method by the filling system 100 will be described. FIG. 2 is a sequence diagram showing from blending to filling, and FIG. 3 is a time schedule of blending. In FIG. 2, for the sake of convenience of explanation, there are parts where each block of storage in the storage tank 30, mixing in the mixing unit 40, and filling in the filling unit 50 are not explicitly shown. For example, during the first blending, each block of storage, mixing, and filling is not explicitly shown. However, actually, even during the first blending, storage, mixing, and filling are performed using the stock solution blended the previous day. Also, FIG. 3 shows a time schedule as an example, and the time schedule is appropriately adjusted according to the actual progress of work or adjustment of the production volume, etc.

[0034] As shown in FIG. 2, the filling system 100 includes a preparation unit 10, a sterilization unit 20, a storage tank 30, a mixing unit 40, and a filling unit 50. The preparation unit 10 is a unit for preparing the stock solution, and has an extraction device 61, a preparation tank 11, and other buffer tanks and the like. Further, the sterilization unit 20 is a unit for sterilizing the stock solution supplied from the preparation unit 10, and has a sterilization device 21 and the like. The storage tank 30 stores the sterilized stock solution, which is supplied to the mixing unit 40.

[0035] The sterilized stock solution is sent from the sterilization unit 20 to the storage tank 30. For example, the stock solution is sent from the sterilization unit 20 to the storage tank 30 at any timing during the preparation time period. As an example, the stock solution is sent to the sterilization unit 20 following the completion of preparation, and then sent to the storage tank 30 following sterilization. And during the non-preparation time period, the stock solution is not sent from the sterilization unit 20 to the storage tank 30. Since the storage tank 30 stores the sterilized stock solution, the stock solution can be stored for a long time without being subject to time limitations due to the allowable residence time (for example, 3 hours to 24 hours). Also, since the allowable residence time is not exceeded during storage, it is not necessary to discard the stock solution that has exceeded the allowable residence time. Therefore, it is possible to eliminate the discarded stock solution or reduce the amount of the discarded stock solution.

[0036] Specifically, the storage tank 30 has a first tank 30A as an example of at least one first storage tank that stores the stock solution supplied during the preparation time period. The storage tank 30 also has a third tank 30C as an example of at least one second storage tank that stores the stock solution supplied during the non-preparation time period. Further, the storage tank 30 has a second tank 30B and a fourth tank 30D that function as the first storage tank and the second storage tank. That is, the second tank 30B and the fourth tank 30D store the stock solution supplied during the preparation time period and the stock solution supplied during the non-preparation time period.

[0037] However, the roles of the first tank 30A, the second tank 30B, the third tank 30C, and the fourth tank 30D may be switched to any of the roles as the first storage tank, the second storage tank, or both. For example, the first tank 30A that has only functioned as the first storage tank may function only as the second storage tank on another day. Similarly, the third tank 30C that has only functioned as the second storage tank may function only as the first storage tank on another day. As an example, the role may be switched due to reasons such as cleaning of the storage tank 30. Furthermore, all the storage tanks 30 may function as both the first storage tank and the second storage tank.

[0038] In addition, the storage tank 30 may have a capacity capable of storing the stock solution of the target storage amount according to the total filling amount of the beverage in the non-blending time zone. For example, the total capacity of the first storage tank and the second storage tank is set to be capable of storing the stock solution of the target storage amount. In the example of FIG. 2, the total capacity of the first tank 30A, the second tank 30B, the third tank 30C, and the fourth tank 30D is set to be capable of storing the stock solution of the target storage amount. However, the total capacity of the plurality of storage tanks 30 may be more than the target storage amount.

[0039] Furthermore, the second storage tank may have a capacity capable of storing the stock solution of the target storage amount according to the total filling amount of the beverage in the non-blending time zone. In this case, when there are a plurality of second storage tanks, the total capacity of the plurality of second storage tanks is set to be capable of storing the stock solution of the target storage amount. However, the total capacity of the plurality of second storage tanks may be more than the target storage amount.

[0040] The mixing unit 40 manufactures a beverage by mixing a diluent with the stock solution supplied from the first storage tank or the second storage tank in a sterile environment. The mixing unit 40 is a unit having a sterile blender 41, a buffer tank, and the like. For example, the mixing unit 40 mixes a diluent in an amount equal to or greater than the amount of the stock solution with the stock solution. As an example, the stock solution is a 2-fold concentrate and is diluted with a diluent in an amount equal to the stock solution. As another example, the stock solution is a 4-fold concentrate and is diluted with a diluent in an amount three times that of the stock solution.

[0041] Alternatively, the stock solution may be a liquid diluted with a diluent in an amount less than the stock solution, such as a 1.5-fold concentrate or a 1.8-fold concentrate. However, since the stock solution is a high-concentration concentrate, the time or number of times of the blending process can be reduced. For example, if the stock solution is a 2-fold concentrate, the number of times of the blending process can be reduced by half compared to the case where the stock solution is not diluted. Further, if the stock solution is a 4-fold concentrate, the number of times of the blending process can be reduced to one-fourth. Thereby, a beverage in an amount that can be continuously filled over 24 hours can be blended with room to spare only during the blending time zone. Also, the number of workers required for the blending operation can be reduced.

[0042] Furthermore, since the stock solution is a high-concentration concentrate, the capacity or number of the storage tanks 30 required to store the stock solution can be reduced. For example, if the stock solution is a 2-fold concentrate, the capacity or number of the storage tanks 30 can be reduced by half compared to the case where the stock solution is not diluted. Further, if the stock solution is a 4-fold concentrate, the capacity or number of the storage tanks 30 can be reduced to one-fourth. Thereby, since a smaller storage tank 30 can be used, the space for installing the storage tank 30 can be reduced.

[0043] The stock solution concentrated in this way is blended in the blending unit 10. Further, the blending unit 10 may be provided with a concentrating device that concentrates the liquid blended in the blending tank 11. In this specification, it is described as being included in "blending" including the concentrating process of the blended liquid. Also, in this specification, the liquid obtained through the concentrating process is also described as being included in the "stock solution".

[0044] The filling unit 50 is a unit that fills the manufactured beverage into a container, and has a filling device 51, a buffer tank, and the like. Further, the filling unit 50 may fill a beverage at room temperature. Since the beverage is manufactured by mixing the diluent with the sterilized stock solution in the mixing unit 40, a beverage at room temperature can be filled. As an example, room temperature is a temperature included in the range from 5 degrees Celsius to 35 degrees Celsius.

[0045] For example, the container into which the beverage is filled in the filling unit 50 is a PET bottle. As an example, the filling system 100 includes a PET bottle molding device, and the molded PET bottle is conveyed to the filling device 51. For example, the molding device molds a PET bottle by blow molding. Note that the molding device is provided as a part of the filling unit 50 or separately from the filling unit 50.

[0046] In the filling method shown in FIG. 2, the stock solution is prepared in the preparation unit 10. Specifically, the first preparation, the second preparation, the third preparation, the fourth preparation, and the fifth preparation are performed once each during the preparation time period. And during the non-preparation time period, no preparation is performed in the preparation unit 10. Further, when each preparation is completed, the prepared stock solution is sent to the sterilization unit 20.

[0047] In the sterilization unit 20, the stock solution supplied from the preparation unit 10 is sequentially sterilized. And the sterilized stock solution is sent to the storage tank 30 as a sterile stock solution. And in each storage tank 30, the inflowing sterile stock solution is stored. For example, the sterile stock solution supplied only during the preparation time period is stored in the first tank 30A as the first storage tank. Also, the sterile stock solution supplied only during the non-preparation time period is stored in the third tank 30C as the second storage tank. Further, the sterile stock solution supplied during both the preparation time period and the non-preparation time period is stored in the second tank 30B and the fourth tank 30D as the first storage tank and the second storage tank.

[0048] Also, in each storage tank 30, the stored sterile stock solution is supplied to the mixing section 40. Here, the inflow rate of the sterile stock solution (i.e., the inflow amount per unit time) is higher than the outflow rate of the sterile stock solution (i.e., the outflow amount per unit time). Therefore, when inflow and outflow occur simultaneously, the storage amount of the sterile stock solution in each storage tank 30 increases over time.

[0049] As an example, first, the sterile stock solution is sent to the first tank 30A. Then, when the storage amount in the first tank 30A reaches the capacity, the sending destination of the sterile stock solution is switched to the second tank 30B, and the sterile stock solution is sent to the second tank 30B. Note that the supply of the sterile stock solution to the mixing section 40 continues even after the switching of the sending destination. Therefore, the storage amount of the sterile stock solution in the first tank 30A decreases over time. After that, when the storage amount in the second tank 30B reaches the capacity, the sending destination of the sterile stock solution is switched to the third tank 30C, and the sterile stock solution is sent to the third tank 30C. Further, when the storage amount in the second tank 30B reaches the capacity, the sending destination of the sterile stock solution is switched to the third tank 30C, and the sterile stock solution is sent to the third tank 30C.

[0050] Then, when the storage amount in the third tank 30C reaches the capacity, the sending destination of the sterile stock solution is switched to the fourth tank 30D, and the sterile stock solution is sent to the fourth tank 30D. Further, when the storage amount in the fourth tank 30D reaches the capacity, the sending destination of the sterile stock solution is switched to the first tank 30A, and the sterile stock solution is sent to the first tank 30A. After that, when the storage amount in the first tank 30A reaches the capacity, the formulation is completed.

[0051] On the next day, the supply from the first tank 30A is carried out. When the first formulation is completed, the sterile stock solution is sent to the first tank 30A again. Note that the order of storage in each storage tank 30 is arbitrary. For example, the fourth tank 30D may receive the sterile stock solution first. Also, each storage tank 30 may be washed when all the sterile stock solution is supplied.

[0052] In the mixing unit 40, the undiluted solution sent from the preparation unit 10 and the diluent are sequentially mixed to produce a beverage. Then, the produced beverage is sent from the mixing unit 40 to the filling unit 50. Thereafter, in the filling unit 50, the produced beverage is filled into a container to produce a container-packed beverage. Note that, as an example of the container, the filling unit 50 accepts a formed PET bottle. Then, the filling unit 50 fills the received PET bottle with the beverage.

[0053] [An Example of the Preparation Schedule] Subsequently, with reference to FIG. 3, an example of the preparation schedule will be described. FIG. 3 shows the preparation schedule starting exactly at 7:00 and passing through 6:00 of the next day. According to this preparation schedule, the preparation process in the preparation unit 10, the sterilization process in the sterilization unit 20, the storage process in the storage tank 30, the mixing process in the mixing unit 40, and the filling process in the filling unit 50 are performed. Note that the preparation process includes other processes such as the process of preparing raw materials, etc. and the process of cleaning the equipment, etc. Also, other processes such as the process of forming a container may be included from the preparation process to the filling process.

[0054] In the example shown in FIG. 3, the beverage is filled on the premise of the following conditions. However, the actual mode from preparation to filling is not limited to these conditions. Specifically, the undiluted solution to be prepared is a 4-fold concentrated solution, and the target storage volume is 194,400 L. Also, the number of storage tanks 30 is four, and the capacity of each storage tank 30 is 35,000 L. Also, the number of preparation tanks 11 is two, and the capacity of each preparation tank 11 is 45,000 L. Also, the amount of undiluted solution prepared in one preparation process is 40,000 L. Also, the inflow rate into each storage tank 30 is 20,000 L / h, and the outflow rate from each storage tank 30 is 8,100 L / h.

[0055] Also, the number of containers filled per minute is 900, and the capacity of each container is 0.6L. Therefore, the total amount of beverage filled in 24 hours is 777,600L. Also, the blending time period is from 7:00 to 22:30, and the non-blending time period is from 22:30 to 7:00. Therefore, the length of the non-blending time period is 8 hours and 30 minutes, and the total amount of beverage filled during the non-blending time period is 275,400L. Therefore, the total amount of the stock solution, which is 4 times the concentrated solution required during the non-blending time period, is 68,850L. However, during the blending time period, the stock solution is also required to manufacture beverages after the fifth blending is completed and before the first blending is completed. Therefore, the target storage volume of the storage tank 30 is set to 194,400L.

[0056] First, in the 3 hours from 7:00 to 9:00, preparations such as preparing raw materials are carried out as preparatory work for blending. After that, in the first blending tank, the first blending is carried out in 2 hours from 10:00 to 11:00. When the first blending is completed, in 1 hour and 30 minutes from 12:00 to 13:30, the stock solution is sent to the first tank 30A. Then, in the first tank 30A, the inflowing stock solution is stored, and the stock solution supplied to the mixing unit 40 flows out. Here, due to the difference between the inflow rate and the outflow rate, the storage volume increases by 11,900L per hour. Therefore, the storage volume of the first tank 30A reaches its capacity around 15:00, and the destination of the stock solution is switched to the second tank 30B.

[0057] In addition, in FIG. 3, the destination of the stock solution is switched at 15:00. However, in terms of calculation, the time required for the storage volume of the first tank 30A to reach its capacity is 2 hours and 57 minutes. Therefore, the storage volume of the first tank 30A reaches its capacity at 14:57. However, for the sake of convenience in explanation, assuming that the situation changes in 30-minute units, it is assumed that the capacity is reached at 15:00. Also, in the following explanations, when it does not match the calculated time, the timing of switching the destination, the timing of starting or stopping the supply, etc. are changed to the assumed conditions. In reality, when the calculated timing does not match the blending schedule, the time of the subsequent process can be shifted forward or backward, or the stock solution can be temporarily stored in the buffer tank to adjust the schedule.

[0058] Returning to FIG. 3, in the first tank 30A, only the supply of the stock solution is performed when the storage amount reaches the capacity, and the supply is stopped at 19:30. Also, the liquid feeding of the stock solution from the first blending tank is stopped at 13:30. In parallel, the second blending is being performed in the second blending tank, and the second blending is completed at 14:00. Thereafter, the third blending, the fourth blending, and the fifth blending, and the liquid feeding of the stock solution to the storage tank 30 are performed. Then, the fifth blending ends at 20:00, and the liquid feeding of the stock solution to the storage tank 30 ends at 22:30.

[0059] Also, in each storage tank 30, only the storage of the inflowing stock solution is performed while the liquid feeding to other storage tanks 30 is being performed. And in the second tank 30B, the storage amount reaches the capacity at 17:00. Also, in the third tank 30C, the storage amount reaches the capacity at 19:00. Also, in the fourth tank 30D, the storage amount reaches the capacity at 21:00. Thereafter, the stock solution is sent to the first tank 30A again, and the storage amount reaches the capacity at 23:00. Also, the supply of the stored stock solution is performed in the order from the first tank 30A to the fourth tank 30D.

[0060] The supply of the stock solution from the fourth tank 30D to the mixing section 40 starts at 4:30 the next day and ends at 9:00. Then, the supply of the stock solution from the first tank 30A to the mixing section 40 starts at 9:00. In FIG. 3, the supply from the fourth tank 30D from 7:00 to 9:00 corresponds to the supply during the blending time zone of the next day. Also, the supply from the first tank 30A from 9:00 to 12:00 also corresponds to the supply during the blending time zone of the next day. Thereafter, the blending and supply according to the above-described schedule are repeated.

[0061] As a result, the first tank 30A stores only the stock solution to be supplied to the mixing section 40 during the blending time period and functions as the first storage tank. Also, the third tank 30C stores only the stock solution to be supplied to the mixing section 40 during the non-blending time period and functions as the second storage tank. Then, the second tank 30B and the fourth tank 30D store both the stock solution to be supplied to the mixing section 40 during the blending time period and the stock solution to be supplied to the mixing section 40 during the non-blending time period, and function as the first storage tank and the second storage tank.

[0062] According to the filling system 100 described above, the number of workers engaged in the blending operation during the non-blending time period can be reduced, and the shortage of workers can be addressed. Also, since the filling of beverages can be continued during the non-blending time period, a decrease in the quantity of products manufactured can be prevented. Furthermore, by using a high-concentration stock solution, the time or number of times of the blending process can be reduced, and the number of necessary workers can also be reduced. And during the blending time period, the stock solution can be blended with a margin. Also, the capacity or number of the storage tanks 30 required to store the stock solution can be reduced. Thereby, the space for installing the storage tanks 30 can be reduced.

[0063] As described above, the present invention has been described with reference to each embodiment, but the present invention is not limited to the above embodiments. Inventions modified within the scope not contrary to the present invention, and inventions equivalent to the present invention are also included in the present invention. Also, each embodiment, each modified form, and the technical means included in each embodiment or each modified form can be appropriately combined within the scope not contrary to the present invention.

[0064] For example, the filling system 100 may further have a supply path for filling the stock solution into a container. In this case, a supply path connecting the sterilizing device 21 and the filling device 51 is provided. And the sterilized stock solution is supplied to the filling device 51 directly from the sterilizing device 21 or indirectly via a buffer tank or the like. A customer who purchases a beverage in a container filled with such a stock solution will dilute the stock solution with water or the like and then drink it.

[0065] Also, the switching of the destination of the stock solution from each storage tank 30 may be performed while the stock solution remains in the storage tank 30. As an example, before one storage tank 30 becomes empty and while the stock solution remains, the feeding of the stock solution from another storage tank 30 may be started.

[0066] Some or all of the above embodiments may be described as follows in the appended claims, but are not limited thereto.

[0067] (Appended Claim 1) A filling system for filling a container with a beverage produced by mixing a diluent with a stock solution in a preparation time period for preparing the stock solution from a raw material and a non-preparation time period for stopping the preparation of the stock solution, a preparation unit for preparing the stock solution, a sterilization unit for sterilizing the stock solution supplied from the preparation unit, at least one first storage tank for storing the sterilized stock solution and supplied during the preparation time period, at least one second storage tank for storing the sterilized stock solution and supplied during the non-preparation time period, a mixing unit for producing the beverage by mixing the diluent with the stock solution supplied from the first storage tank or the second storage tank in a sterile environment, and a filling unit for filling the produced beverage into the container.

[0068] (Appended Claim 2) The filling system according to Appended Claim 1, wherein the second storage tank has a capacity capable of storing the stock solution at a target storage amount corresponding to the total filling amount of the beverage during the non-preparation time period.

[0069] (Appended Claim 3) The filling system according to Appended Claim 2, wherein the target storage amount is set based on at least the length of the non-preparation time period and the number of the containers used during the non-preparation time period.

[0070] (Appended Claim 4) A control device for acquiring or calculating the target storage amount, The filling system according to appendix 2 or 3, wherein the control device causes the target storage amount to be displayed on a display device.

[0071] (Appendix 5) The filling system according to any one of appendices 1 to 4, wherein the filling unit fills the beverage at normal temperature.

[0072] (Appendix 6) The filling system according to any one of appendices 1 to 5, wherein the mixing unit mixes the diluent in an amount equal to or more than the amount of the stock solution with the stock solution.

[0073] (Appendix 7) The filling system according to any one of appendices 1 to 6, wherein the container is a PET bottle.

[0074] (Appendix 8) A filling method for filling a container with a beverage produced by mixing a diluent into a stock solution in a preparation time zone for preparing the stock solution from raw materials and a non-preparation time zone for stopping the preparation of the stock solution, Preparing the stock solution in a preparation unit, Sterilizing the stock solution supplied from the preparation unit, Storing the sterilized stock solution, which is the stock solution supplied during the preparation time zone, in at least one first storage tank, Storing the sterilized stock solution, which is the stock solution supplied during the non-preparation time zone, in at least one second storage tank, In a mixing unit in a sterile environment, mixing the diluent into the stock solution supplied from the first storage tank or the second storage tank to produce the beverage, A filling method for filling the produced beverage into the container.

Explanation of Signs

[0075] 10: Preparation unit 20: Sterilization unit 30: Storage tank 30A: First tank (first storage tank) 30C: Third Tank (Second Storage Tank) 40: Mixing Section 50: Filling Section 70: Control Device 100: Filling System

Claims

1. A filling system for filling a container with a beverage produced by mixing a diluent with a stock solution in a preparation time period for preparing the stock solution from raw materials and a non-preparation time period for stopping the preparation of the stock solution, the filling system comprising: a preparation unit for preparing the stock solution; a sterilization unit for sterilizing the stock solution supplied from the preparation unit; at least one first storage tank for storing the sterilized stock solution supplied during the preparation time period; at least one second storage tank for storing the sterilized stock solution supplied during the non-preparation time period; a mixing unit for producing the beverage by mixing the diluent with the stock solution supplied from the first storage tank or the second storage tank in a sterile environment; and a filling unit for filling the produced beverage into the container.

2. The filling system according to claim 1, wherein the second storage tank has a capacity capable of storing the stock solution at a target storage amount corresponding to the total filling amount of the beverage during the non-preparation time period.

3. The filling system according to claim 2, wherein the target storage amount is set based on at least the length of the non-preparation time period and the number of the containers used during the non-preparation time period.

4. The filling system according to claim 2 or 3, further comprising a control device for obtaining or calculating the target storage amount, wherein the control device causes the target storage amount to be displayed on a display device.

5. The filling system according to any one of claims 1 to 3, wherein the filling unit fills the beverage at room temperature.

6. The filling system according to any one of claims 1 to 3, wherein the mixing unit mixes the diluent in an amount equal to or greater than the amount of the stock solution with the stock solution.

7. The filling system according to any one of claims 1 to 3, wherein the container is a PET bottle.

8. A filling method for filling a container with a beverage produced by mixing a diluent with a stock solution in a preparation time period for preparing the stock solution from raw materials and a non-preparation time period for stopping the preparation of the stock solution, the filling method comprising: preparing the stock solution in a preparation unit; sterilizing the stock solution supplied from the preparation unit; storing the sterilized stock solution supplied during the preparation time period in at least one first storage tank; and storing the sterilized stock solution supplied during the non-preparation time period in at least one second storage tank. In the mixing section under a sterile environment, the diluent is mixed with the stock solution supplied from the first storage tank or the second storage tank to produce the beverage, and the produced beverage is filled into the container. A filling method.

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