Method for reusing sterile water and sterile filling machine for reusing sterile water

Abstract

This invention provides a method for reusing sterile water used in a sterile filling machine, which reduces energy waste of the sterile water used in the machine, and a sterile filling machine that reuses sterile water. [Solution] In an aseptic filling machine that sterilizes a transported container, fills the sterilized container with sterilized contents in an aseptic atmosphere, and seals the container filled with contents with a sterilized lid in an aseptic atmosphere, each part that performs sterilization, filling, and sealing is shielded by a chamber, sterile water supplied to a rinsing device chamber to rinse the sterilized container is recovered, the recovered sterile water is supplied to a heat exchange device, and heat is exchanged with water before sterilization to produce the sterile water.

Description

Technical Field

[0001] The present disclosure relates to a method for reusing aseptic water for rinsing a cleaning liquid used for cleaning an aseptic filling machine or a sterilizing liquid used for sterilizing an aseptic filling machine, and aseptic water for rinsing a container or a cap after sterilization, in an aseptic filling machine for filling beverages into containers such as PET bottles.

Background Art

[0002] Conventionally, in an aseptic filling machine for beverages, when switching the type of beverage to be filled into a container such as a bottle from, for example, a tea beverage to a milk coffee, first, CIP (Cleaning in Place) is performed inside the beverage supply system piping of this aseptic filling machine, and then SIP (Sterilizing in Place) is performed (see Patent Document 1).

[0003] CIP is performed by flowing a cleaning liquid obtained by adding an alkaline agent such as caustic soda to water, and then a cleaning liquid obtained by adding an acidic agent to water, through the flow path from the inside of the pipeline of the beverage filling flow path to the filling nozzle of the filling machine. Thereby, residues of the previous beverage adhering to the beverage filling flow path are removed (see Patent Documents 1, 2, and 3).

[0004] SIP is performed, for example, by flowing steam, hot water, etc. through the beverage filling flow path cleaned by the above CIP. Thereby, the inside of the beverage filling flow path is sterilized and brought into an aseptic state (see Patent Document 1).

[0005] A sterile filling machine includes a sterilization device for sterilizing containers, a filling machine for automatically filling containers with beverages, and a sealing device for sealing containers with lids. The sterilization device, filling machine, and sealing device are enclosed in a chamber that can maintain a sterile atmosphere and are shielded from the outside. Since splashes of beverages from the previous filling operation adhere to the inside of the chamber that shields the filling machine and sealing device, when switching the type of beverage to be filled, the chamber is cleaned to remove beverage splashes that have adhered to the inner wall of the chamber and the outer surface of the equipment inside the chamber during the previous filling operation. The chamber is cleaned, for example, by spraying a cleaning solution containing a cleaning agent into the chamber in a shower-like manner (see Patent Document 4).

[0006] Furthermore, since microorganisms may enter the chamber during various operations when switching between types of beverages, sterilization of the chamber is also performed. Sterilization of the chamber is performed, for example, by supplying a disinfectant solution containing disinfectants such as peracetic acid and hydrogen peroxide into the chamber in the form of a mist or shower, and then blowing hot air into the chamber to dry the remaining disinfectant solution (see Patent Document 4).

[0007] When cleaning or sterilizing the chamber, sterile water is sprayed into the chamber to rinse away the cleaning or sterilizing solution. The sterile filling machine is equipped with a sterilization device that heat-sterilizes water to produce the necessary sterile water (see Patent Document 5).

[0008] As described above, sterile water is used for cleaning or sterilizing the chamber before the sterile filling machine is in operation, and when the sterile filling machine is in operation, the containers and lids are sterilized in the machine. Sterile water is used to wash away any sterilizing solution adhering to the sterilized containers and lids. [Prior art documents] [Patent Documents]

[0009] [Patent Document 1] Japanese Patent Publication No. 2007-22600 [Patent Document 2] Japanese Patent Publication No. 2007-331801 [Patent Document 3] Japanese Patent Publication No. 2000-153245 [Patent Document 4] Patent No. 6056930 [Patent Document 5] Japanese Patent Publication No. 2010-189034 [Disclosure of the Invention] [Problems that the invention aims to solve]

[0010] Aseptic filling machines require sterile water to rinse the cleaning solution used to clean the chambers that make up the machine, or the disinfectant solution used to sterilize the chambers, and sterile water to rinse the containers or caps after sterilization, resulting in large quantities of sterile water being used. When cleaning or sterilizing the chambers, sterile water is sprayed into the chambers to wash away the cleaning solution or disinfectant solution. In addition to the sterilization equipment used to sterilize the beverages to be filled into the containers, a sterilization device is needed to produce sterile water in order to produce the sterile water used when cleaning or sterilizing the chambers before the machine is put into operation, and to produce the sterile water used when cleaning the inside of the containers after sterilization, cleaning the caps after sterilization, and cleaning the outside of the container opening after beverage filling during the operation of the machine.

[0011] It is wasteful to simply drain the large amount of sterile water supplied to the chamber for cleaning or sterilization after use. However, the method of decomposing the disinfectant contained in the sterile water after cleaning and then sterilizing the water again is complicated and requires additional equipment.

[0012] Discharging the sterile water supplied to the chamber of a sterile filling machine during and before operation is a waste of energy. To avoid this energy waste, the sterile water supplied to the chamber needs to be reused, and there is a demand for sterile filling machines that reuse the used sterile water.

[0013] This disclosure aims to provide a method for reusing sterile water used in a sterile filling machine, and a sterile filling machine that reuses sterile water, thereby eliminating energy waste of the sterile water used in the sterile filling machine. [Means for solving the problem]

[0014] The method for reusing sterile water according to this disclosure is an aseptic filling machine that sterilizes a transported container, fills the sterilized container with sterilized contents in a sterile atmosphere, and seals the container filled with contents with a sterilized lid in a sterile atmosphere, wherein each part that performs sterilization, filling, and sealing is shielded by a chamber, sterile water supplied to a rinsing device chamber to rinse the sterilized container is recovered, the recovered sterile water is supplied to a heat exchange device, and heat is exchanged with water before sterilization for producing the sterile water. A method for reusing sterile water according to another embodiment of the present disclosure involves a sterile filling machine that sterilizes a transported container, fills the sterilized container with sterilized contents in a sterile atmosphere, and seals the container filled with contents with a sterilized lid in a sterile atmosphere, wherein each part performing the sterilization, filling, and sealing is shielded by a chamber, sterile water at 50°C or higher and 90°C or lower that has been sprayed into the chamber to wash away the cleaning solution or sterilizing solution is recovered, the recovered sterile water is supplied to a heat exchanger, and heat is exchanged with water before sterilization for producing the sterile water.

[0015] Furthermore, in the method for reusing sterile water according to this disclosure, it is preferable to use the heat-exchanged sterile water to clean the outer surface of the sealed container.

[0016] The method for reusing sterile water according to this disclosure is an aseptic filling machine that sterilizes a transported container, fills the sterilized container with sterilized contents in a sterile atmosphere, and seals the container filled with contents with a sterilized lid in a sterile atmosphere, wherein each part that performs sterilization, filling, and sealing is shielded by a chamber, and before sterilization of the inside of each chamber, the inside of the chamber that is heavily contaminated by the contents splashing inside the chamber is cleaned by spraying hot water, boiling water, an alkaline cleaning solution mainly composed of caustic soda, or an acidic cleaning solution.

[0017] Furthermore, in the method for reusing sterile water according to this disclosure, it is preferable not to clean the sterilization device chamber that shields the sterilization device that sterilizes the container before sterilization.

[0018] The method for reusing sterile water according to this disclosure is an aseptic filling machine that sterilizes a transported container, fills the sterilized container with sterilized contents in a sterile atmosphere, and seals the container filled with contents with a sterilized lid in a sterile atmosphere, wherein each part that performs sterilization, filling, and sealing is shielded by a chamber, the chamber is cleaned and sterilized before the aseptic filling machine is operated, a cleaning solution is sprayed to perform the cleaning, non-sterile water is sprayed to wash away the cleaning solution, a sterilizing solution is sprayed to perform the sterilization, and sterile water is sprayed to wash away the sterilizing solution.

[0019] Furthermore, in the method for reusing sterile water according to this disclosure, it is preferable to recover the heated sterile water that has been sprayed into each chamber to wash away the cleaning solution used for washing or the disinfecting solution used for sterilization, and to supply the recovered sterile water to a heat exchanger and exchange heat with the water before sterilization for producing the sterile water.

[0020] Furthermore, in the method for reusing sterile water according to this disclosure, it is preferable that the temperature of the sterile water supplied into the chamber is 60°C or higher and 100°C or lower.

[0021] The aseptic filling machine for reusing aseptic water according to the present disclosure includes a sterilization device for sterilizing the conveyed containers, a filling device for filling the sterilized containers sterilized by the sterilization device with sterilized contents in an aseptic atmosphere, a sealing device for sealing the containers filled with the contents with sterilized lid materials in an aseptic atmosphere, a chamber for shielding the sterilization device, the filling device, and the sealing device, an aseptic water recovery device for recovering the aseptic water supplied to the rinse device chamber for rinsing the sterilized containers, and a heat exchange device for heat-exchanging the aseptic water recovered by the aseptic water recovery device with the water before sterilization for manufacturing the aseptic water. The aseptic filling machine for reusing aseptic water according to another embodiment of the present disclosure includes a sterilization device for sterilizing the conveyed containers, a filling device for filling the sterilized containers sterilized by the sterilization device with sterilized contents in an aseptic atmosphere, a sealing device for sealing the containers filled with the contents with sterilized lid materials in an aseptic atmosphere, a chamber for shielding the sterilization device, the filling device, and the sealing device, an aseptic water recovery device for recovering the aseptic water sprayed into the chamber at 50°C or higher and 90°C or lower to wash away the cleaning liquid or the sterilizing liquid, and a heat exchange device for heat-exchanging the aseptic water recovered by the aseptic water recovery device with the water before sterilization for manufacturing the aseptic water.

[0022] Also, in the aseptic filling machine for reusing aseptic water according to the present disclosure, it is preferable that the heat-exchanged aseptic water is configured to be used for cleaning the outer surface of the sealed container.

[0023] Also, in the aseptic filling machine for reusing aseptic water according to the present disclosure, it is preferable that the temperature of the aseptic water supplied into the chamber is configured to be 60°C or higher and 100°C or lower.

Effects of the Invention

[0024] According to this disclosure, sterile water supplied into the chamber for rinsing off cleaning solution used for cleaning the chamber before operation of the sterile filling machine or disinfectant solution used for sterilization of the chamber, or sterile water supplied into the chamber for rinsing containers or lids to be sterilized when the sterile filling machine is in operation, can be reused by exchanging heat between the sterile water supplied into the chamber and the unsterilized water supplied to produce the sterile water, thereby increasing energy utilization efficiency without wasting the sterile water supplied into the chamber. [Brief explanation of the drawing]

[0025] [Figure 1] This is a plan view showing a schematic of an aseptic filling machine according to an embodiment of the present disclosure. [Figure 2A] This shows a preform supplied to the heating section of a sterile filling machine according to an embodiment of the present disclosure. [Figure 2B] The above diagram shows the preform heating process, which is part of the heating section of the aseptic filling machine. [Figure 2C] This shows the blow molding process, which is one of the processes in the molding section of the above-mentioned sterile filling machine. [Figure 2D] This shows the container removal process, which is part of the molding process of the aseptic filling machine described above. [Figure 2E-1] This shows the disinfectant gas spraying process, which is part of the sterilization section of the above-mentioned aseptic filling machine, and is performed with the container shielded by a tunnel. [Figure 2E-2] This diagram shows the process of spraying disinfectant gas by inserting a disinfectant gas spraying nozzle into a container. [Figure 2F-1] This shows the sterile water rinsing process in the rinsing section of the above-mentioned sterile filling machine, with the container in an upright position. [Figure 2F-2] This shows the sterile water rinsing process with the container in an inverted position. [Figure 2G] The filling process is shown as part of the filling section of the above-mentioned sterile filling machine. [Figure 2H] This shows the sealing process, which is part of the filling section of the aseptic filling machine described above. [Figure 3]This disclosure shows a recovery device and a heat exchange device for sterile water supplied for use in cleaning or sterilizing the chamber of a sterile filling machine according to an embodiment of this disclosure. [Figure 4] This invention illustrates a recovery device and a heat exchange device for sterile water supplied to the rinsing chamber of a sterile filling machine according to an embodiment of this disclosure. [Modes for carrying out the invention]

[0026] The embodiments for implementing this disclosure will be described below with reference to the drawings.

[0027] Figure 1 shows an aseptic filling machine according to an embodiment of the present disclosure. The aseptic filling machine comprises a preform heating device for heating a supplied preform, a molding device for molding the heated preform into a container, an inspection device for the molded container, a sterilization device for sterilizing the container, a rinsing device for rinsing the sterilized container with sterile water, a filling device for filling the rinsed container with sterilized contents in a sterile atmosphere, a sealing device for sealing the container filled with contents with a sterilized lid material in a sterile atmosphere, and a discharge device for discharging the sealed container, wherein the aseptic filling machine comprises a sterile water production device for producing sterile water supplied to a chamber that shields each device, and sterile water supplied to each chamber Figure 1 illustrates the general layout of an aseptic filling machine equipped with a sterile water recovery device and a heat exchange device that exchanges heat between the recovered sterile water and the water supplied to the sterile water production device. Figures 2A to 2H describe the details of each device. According to this embodiment, sterile water used for cleaning or sterilizing each chamber of the aseptic filling machine, and sterile water used for rinsing sterilized containers or lids, can be reused by exchanging heat with unsterilized water, thereby reducing energy consumption.

[0028] (Summary of the embodiment) As shown in Figure 1, the aseptic filling machine according to this embodiment includes a preform supply device 4 for supplying a preform 1, a heating device 6 for heating the preform 1 to a temperature suitable for molding it into a container 2, a molding device 10 for molding the heated preform 1 into a container 2, an inspection wheel 14 for inspecting the molded container 2, a sterilization device 17 for sterilizing the molded container 2, a rinsing device 19 for rinsing the sterilized container 2, a filling device 21 for filling the rinsed container 2 with sterilized contents in an aseptic atmosphere, a lid material sterilization device 31 for sterilizing the lid material 3 which is a sealing member, a sealing device 24 for sealing the container 2 filled with contents using the sterilized lid material 3 in an aseptic atmosphere, a discharge device 28 for placing the sealed container 2 onto a discharge conveyor 30, and a discharge unit for discharging the container 2 to a non-sterile zone via the discharge conveyor 30. Here, the inspection wheel 14 is optional.

[0029] The heating device 6 is shielded by the heating device chamber 7, the molding device 10 and inspection wheel 14 by the molding device chamber 11, the sterilization device 17 by the sterilization device chamber 18, the rinsing device 19 by the rinsing device chamber 20, the filling device 21 by the filling device chamber 23, the sealing device 24 by the sealing device chamber 25, and the discharge device 28 by the discharge device chamber 29. The lid material sterilization device 31 is also shielded by a chamber. An atmosphere isolation chamber 16 is provided between the molding device chamber 11 and the sterilization device chamber 18 to prevent the disinfectant gas or mist or mixture thereof generated in the sterilization device 17 from flowing into the molding device 10. The disinfectant gas or mist or mixture thereof generated in the sterilization device chamber 18 does not flow into the molding device chamber 11 when the atmosphere isolation chamber 16 is exhausted. Here, the heating device 6 and the molding device 10 may be shielded by a single chamber. Also, the lid material sterilization device 31 and the sealing device 24 may be shielded by a single chamber. Furthermore, the sealing device 24 and the discharge device 28 may also be shielded by a single chamber.

[0030] Before operating the sterile filling machine, each chamber is cleaned and then sterilized. A cleaning solution is used for cleaning each chamber, and a sterilizing solution is used for sterilization; these are sprayed into each chamber. Sterile water is supplied into each chamber to wash away the sprayed cleaning or sterilizing solution. As shown in Figure 1, water is supplied from the water supply tank 33 to the sterile water production device 35, where the supplied water is heated and sterilized to produce sterile water. The produced sterile water is supplied via the sterile water supply piping 36 to the chambers that shield the sterilization device chamber 18, the rinsing device chamber 20, the filling device chamber 23, the sealing device chamber 25, the discharge device chamber 29, and the lid material sterilization device 31. The sterile water supplied to each chamber is heated to enhance the cleaning and sterilization effects.

[0031] The sterilization chamber 18 and the rinsing chamber 20 do not need to be cleaned because there is no concern about contamination by their contents. Also, the rinsing after cleaning does not need to be done with sterile water. Since disinfectant gas, mist, or a mixture thereof is sprayed into the sterilization chamber 18 while the sterile filling machine is in operation, it is not necessary to sterilize the inside of the sterilization chamber 18 before operating the sterile filling machine.

[0032] The sterile water supplied to each chamber is recovered after the washing or disinfecting solution has been rinsed away. The recovered sterile water is collected by the sterile water recovery pipe 37 and then supplied by the heat exchanger 34. The water supplied from tank 33 undergoes heat exchange. The sterile water recovered by the sterile water recovery piping 37 may also undergo heat exchange after being stored in the tank. The heat exchange device 34 may be incorporated into the sterile water production device 35.

[0033] Before the sterile filling machine is put into operation, the sterile water used for cleaning or sterilizing the chamber may be collected, heat-exchanged, and then discharged. Before the sterile filling machine is put into operation, the heat-exchanged sterile water may be used to clean the cleaning device that cleans the outer surface of the sealed container 2. Alternatively, it may be supplied to the sterile water production device 35 and used as water for producing sterile water.

[0034] When the sterile filling machine is in operation, the sterile water supplied to the rinsing chamber 20 or the chamber of the lid material sterilization device 31, and used for rinsing the sterilized container 2 or lid material 3, may be recovered, heat-exchanged, and then used to wash the outer surface of the sealed container 2.

[0035] During operation of the aseptic filling machine, sterile air, sterilized by a sterilization filter, is supplied to the chambers that shield the sterilization chamber 18, rinsing chamber 20, filling chamber 23, sealing chamber 25, discharge chamber 29, and lid material sterilization device 31, which have been sterilized within the chambers. By maintaining positive pressure in each chamber, the sterility of the aseptic filling machine is maintained. The pressure maintained at positive pressure is highest in the filling chamber 23, and decreases as you move upstream to the rinsing chamber 20 and sterilization chamber 18. It also decreases as you move downstream to the sealing chamber 25 and discharge chamber 29. When the atmosphere isolation chamber 16 is evacuated, the pressure inside the atmosphere isolation chamber 16 is maintained at approximately the same level as atmospheric pressure. For example, if the pressure inside the filling chamber 23 is set to between 20 Pa and 40 Pa, the pressure in the other chambers will be lower than the pressure inside the filling chamber 23.

[0036] (Details of the embodiment) First, the preform 1 shown in Figure 2A is continuously transported from the preform supply device 4 shown in Figure 1 to the heating device 6 at a desired speed via the preform supply conveyor 5.

[0037] In this embodiment, the preform 1 is a test tube-shaped, bottomed cylindrical body, and a mouth 1a similar to that of the container 2 shown in Figure 2D is formed at the beginning of its molding process. Male threads are formed in this mouth 1a simultaneously with the molding of the preform 1. In addition, a support ring 1b for transport is formed at the bottom of the mouth 1a of the preform 1. The preform 1 or container 2 is gripped by the gripper 32 via this support ring 1b and travels through the aseptic filling machine. The preform 1 is molded by injection molding, compression molding, etc. The material of the preform 1 is a thermoplastic resin such as polyethylene terephthalate, polyethylene naphthalate, polyethylene furanoate, polypropylene, or polyethylene, and may be a single resin or a mixture of these resins, or may contain recycled thermoplastic resin. Furthermore, to provide barrier properties, a thermoplastic resin such as ethylene-vinyl alcohol copolymer or polyamide with an aromatic amine such as metaxylylenediamine as a monomer may be included as a layer or as a mixture.

[0038] The preform 1 supplied to the heating device 6 is transported by a wheel equipped with numerous grippers 32 at a constant pitch. The preform 1, heated by the heating device 6, is released from the grippers 32 as shown in Figure 2B, and is transported with a spindle 9 inserted into the opening 1a.

[0039] As shown in Figure 2B, the preform 1 is heated by an infrared heater 8 or other heating means to a temperature suitable for subsequent blow molding. This temperature is preferably between 90°C and 130°C.

[0040] Furthermore, the temperature of the opening 1a of the preform 1 is kept below 70°C to prevent deformation and other issues.

[0041] As shown in Figure 2B, the preform 1 has a spindle 9 inserted into its opening 1a, is heated by an infrared heater 8, and is transported by an endless chain while rotating. The spindles 9 are provided at regular intervals on the endless chain. The endless chain is rotated by pulleys. By inserting a mandrel in place of the spindles 9 into the preform 1, it is also possible to transport the preform 1 while rotating it in an inverted state.

[0042] The heated preform 1 is released from the spindle 9, gripped by the gripper 32, and transported to the molding wheel 12 of the molding apparatus 10. The mold 13 provided on the molding wheel 12 blow-moldes the preform 1 into the container 2, as shown in Figure 2C. Multiple molds 13 and blow nozzles are arranged around the molding wheel 12 and rotate at a constant speed around the molding wheel 12 as the molding wheel 12 rotates. When the heated preform 1 arrives, the mold 13 clamps the preform 1. Subsequently, the blow nozzle is joined to the preform 1, and a stretching rod (not shown) is guided into a hole provided in the blow nozzle and inserted into the preform 1. The inserted stretching rod stretches the bottom of the preform 1, causing it to be stretched longitudinally, and at the same time, air or other gas is blown into the preform 1 from the blow nozzle, causing it to be stretched laterally. The preform 1 is stretched longitudinally and laterally within the mold 13, and the container 2 is formed. As shown in Figure 2D, the molded container 2 is removed from the mold 13, the support ring 1b is grasped by the gripper 32 provided on the inspection wheel 14, and the container is transferred to the inspection wheel 14.

[0043] The molded container 2 is inspected by an inspection device 15 located around the inspection wheel 14 for its temperature, body, support ring 1b, top surface of the container opening, bottom surface, etc. If an abnormality is detected, it is discharged to the outside of the aseptic filling machine by a discharge device (not shown). The container inspection is performed inside the molding machine chamber 11, but the inspection device 15 may be shielded by a separate chamber.

[0044] The temperature inspection of container 2 involves checking the surface temperature of container 2 to determine its quality. The temperature sensor is, for example, an infrared thermometer, but other thermometers can also be used. It is necessary for residual heat from the container molding process to remain in container 2 in order to properly sterilize it. The temperature detected by the temperature sensor is preferably 40°C or higher.

[0045] Furthermore, the container body, support ring 1b, top surface of the container opening, and bottom of the container are imaged by a camera, and the condition of each part is inspected. The captured images are processed by an image processing device to determine whether there are any abnormalities such as scratches, foreign objects, deformation, or discoloration. Containers 2 that exceed the acceptable range are judged to be abnormal.

[0046] Containers 2 that are not deemed abnormal by the inspection device 15 are transported to the sterilization device 17 via a wheel in an atmosphere isolation chamber 16 located between the molding device 10 and the sterilization device 17, so as not to allow the disinfectant gas, mist, or mixture thereof generated in the sterilization device 17 to flow into the molding device 10.

[0047] The container 2 transported to the sterilization device 17 is sterilized. Figure 2E-1 shows the process of blowing disinfectant gas onto the container 2 for sterilization. A disinfectant gas blowing nozzle 38 is provided to blow disinfectant gas onto the container 2. The disinfectant gas blowing nozzle 38 is fixed so that the nozzle hole at its tip faces directly towards the opening of the mouth 1a of the container 2 that runs directly below it. In addition, if necessary, below the disinfectant gas blowing nozzle 38 along the path of the container 2, As shown in 2E-1, a disinfectant gas spraying tunnel 39 is provided. There may be one or more disinfectant gas spraying nozzles 38. The disinfectant gas sprayed onto the container 2 flows into the inside of the container 2 and disinfects the inner surface of the container 2. At this time, as the container 2 moves through the disinfectant gas spraying tunnel 39, the disinfectant gas or mist or a mixture thereof flows to the outside surface of the container 2, disinfecting the outside surface of the container 2.

[0048] Alternatively, as shown in Figure 2E-2, the disinfectant gas spraying nozzle 38 may be made to follow the transport of the container 2, and the disinfectant spraying nozzle 38 may be inserted into the container 2 to directly spray disinfectant gas or mist or a mixture thereof onto the inner surface of the container 2. The disinfectant gas or mist or a mixture thereof that overflows from the container 2 collides with the guide member 38a surrounding the disinfectant gas spraying nozzle 38, flows to the outer surface of the container 2, and comes into contact with the outer surface of the container 2. The guide member 38a is provided with a flange portion coaxial with the disinfectant gas spraying nozzle 38 and an annular wall portion protruding outward from the flange portion.

[0049] The disinfectant gas or mist, or mixture thereof, is a disinfectant gasified by a disinfectant gas generator, or a mist formed from condensed gasified disinfectant, or a mixture thereof. The disinfectant gas generator comprises a disinfectant supply unit, which is a two-fluid spray nozzle that supplies the disinfectant in droplet form, and a vaporization unit that heats the disinfectant supplied from the disinfectant supply unit to below its decomposition temperature to vaporize it. The disinfectant supply unit is configured to introduce disinfectant and compressed air from a disinfectant supply passage and a compressed air supply passage, respectively, and spray the disinfectant into the vaporization unit. The vaporization unit is a pipe with a heater sandwiched between its inner and outer walls, and heats and vaporizes the disinfectant blown into this pipe. The vaporized disinfectant gas is ejected outside the vaporization unit from a disinfectant gas spraying nozzle 38. The vaporization unit may be heated by induction heating instead of a heater.

[0050] The disinfectant gas generator is not limited to the structure described above; any device capable of gasifying liquid disinfectants is acceptable.

[0051] The disinfectant gas is sprayed onto the container 2 from the disinfectant gas spraying nozzle 38, as shown in Figure 2E-1 or Figure 2E-2. The amount of disinfectant gas, mist, or mixture thereof sprayed is arbitrary, but the amount sprayed is determined by the amount of disinfectant supplied to the disinfectant gas generator and the spraying time. Multiple disinfectant gas generators may be provided. The amount sprayed also varies depending on the size of the container 2.

[0052] The disinfectant gas generated by the disinfectant gas generator is supplied to the lid material sterilization device 31 and sprayed over the entire surface of the transported lid material 3, thereby sterilizing the lid material 3.

[0053] The disinfectant preferably contains at least hydrogen peroxide. The appropriate content is between 0.5% by mass and 65% by mass. Below 0.5% by mass, the disinfectant may be insufficient, while above 65% by mass, it becomes difficult to handle for safety reasons. Even more preferable is a content between 0.5% by mass and 40% by mass; below 40% by mass, it is easier to handle, and the low concentration reduces the amount of disinfectant remaining in the container 2 after sterilization.

[0054] When hydrogen peroxide is used as the disinfectant, the amount of hydrogen peroxide gas sprayed is as follows. The amount of hydrogen peroxide adhering to the inner surface of container 2 due to the hydrogen peroxide gas sprayed onto the inner surface of container 2 from the disinfectant gas spraying nozzle 38 is preferably 30 μL / container or more and 150 μL / container or less, and more preferably 50 μL / container or more and 100 μL / container or less, as the amount of hydrogen peroxide gas containing 35% by mass of hydrogen peroxide. Furthermore, the hydrogen peroxide concentration of the hydrogen peroxide gas sprayed onto container 2 is preferably 2 mg / L or more and 20 mg / L or less, and more preferably 5 mg / L or more and 10 mg / L or less.

[0055] Furthermore, while disinfectants contain water, they may also contain one or more alcohols such as methyl alcohol, ethyl alcohol, isopropyl alcohol, n-propyl alcohol, and butyl alcohol, ketones such as acetone, methyl ethyl ketone, and acetylacetone, and glycol ethers.

[0056] Furthermore, the disinfectant may contain additives such as peracetic acid, acetic acid and other organic acids, chlorine compounds such as sodium hypochlorite, compounds with bactericidal effects such as ozone, cationic surfactants, nonionic surfactants, and phosphate compounds.

[0057] Container 2, to which the disinfectant has been sprayed, is then sprayed with sterile air as needed. The sterile air is obtained by passing air from a blower through a sterile filter, and it is preferable that the air is heated to 40°C or higher and 70°C or lower. By spraying heated air, the disinfectant is activated, and the disinfecting effect is enhanced. By spraying air, any excess disinfectant remaining in container 2 is removed.

[0058] The lid material 3, which has been sprayed with disinfectant, is then sprayed with sterile air or heated sterile air, similar to the container 2, to enhance the disinfecting effect of the disinfectant and remove any excess disinfectant remaining on the lid material 3.

[0059] The container 2, sterilized by the sterilization device 17, is transported to the rinsing device 19, as shown in Figure 1. As shown in Figure 2F-1, sterile water is sprayed onto the upright container 2 by the container rinsing nozzle 40. The sterile water is produced by the sterile water production device 35, as shown in Figure 1, and supplied to the rinsing device chamber 20 by the sterile water supply pipe 36. The sterile water is sterilized by the sterile water production device 35, but is not cooled to room temperature after sterilization, and is supplied to the rinsing device at a temperature of 60°C or higher and 100°C or lower. The sterile water discharges any remaining disinfectant inside the container 2, decomposes the remaining disinfectant to further enhance the sterilization effect, and also has the effect of removing any foreign matter present inside the container 2. The sterile water sprayed inside the container 2 is discharged by rotating the gripper 32 and inverting the container 2.

[0060] As shown in Figure 2F-2, the container 2 may be placed in an inverted position and sterile water may be sprayed into the container 2. In this case, it is more effective in removing foreign matter than when the container is upright. The container rinsing nozzle 40 may be made vertically movable so that sterile water can be sprayed into the container 2.

[0061] As shown in Figure 1, the container 2, which has been rinsed in the rinsing device 19, is transported to the filling device 21. In the filling device 21, the contents are filled into the container 2 by the filling nozzle 41 using the filling wheel 22 shown in Figure 1, as shown in the filling process shown in Figure 2G. The contents are sterilized in advance, and a fixed amount of beverage or other contents is filled into the container 2 by the filling nozzle 41, which moves synchronously with the container 2.

[0062] The contents, which are mixed in the mixing device and sterilized in the contents sterilization device, are stored in the surge tank and then sent to a head tank located near the filling device 21. From the head tank, the contents are supplied to the filling nozzle 41 and filled into the container 2.

[0063] The container 2, filled with its contents, is transported to the sealing device 24 via the filling wheel 22 shown in Figure 1. In the sealing wheel 26 of the sealing device 24, as shown in the sealing process in Figure 2H, the lid material 3, which is a sealing member sterilized by the lid material sterilization device 31, is supplied to the sealing wheel 26 via the lid material supply wheel and is then wrapped around the opening 1a of the container 2 by a capper (not shown), thereby sealing the container 2.

[0064] The sealed container 2 is transferred from the gripper 32 of the sealing wheel 26 to the gripper 32 of the discharge wheel 27 of the discharge device 28. The container 2 transferred to the discharge wheel 27 is then discharged. The containers are placed on the conveyor belt 30. Once placed on the discharge conveyor belt 30, the containers 2 are discharged to the outside of the aseptic filling machine.

[0065] Before the sterile filling machine is in operation, the inside of each chamber—the sterilization chamber 18, the rinsing chamber 20, the filling chamber 23, the sealing chamber 25, the discharge chamber 29, and the chambers that shield the lid material sterilization device 31—is cleaned and sterilized.

[0066] Before sterilization of each chamber, the chambers downstream from the filling chamber 23 where the contents are filled are cleaned. Chambers that are heavily contaminated due to contents splashing inside are cleaned by spraying them with hot water, boiling water, an alkaline cleaning solution mainly composed of caustic soda, or an acidic cleaning solution. The chambers that shield the sterilization chamber 18, the rinsing chamber 20, the discharge chamber 29, and the lid material sterilization device 31 do not need to be cleaned because the contamination is limited.

[0067] If the contents are changed after a continuous operation of filling beverages into containers using an aseptic filling machine, or if the chamber becomes contaminated with droplets of the contents due to prolonged continuous operation, the aseptic filling machine shall be stopped and the chamber shall be cleaned and sterilized. Chambers that are not contaminated with contents shall be sterilized only.

[0068] Sterile water is sprayed into each chamber to wash away any cleaning solution remaining in the chamber after cleaning or any disinfectant solution remaining in the chamber after disinfection. Sterile water spray nozzles are provided inside the chambers to spray sterile water. Cleaning or disinfection of the chambers may also be performed by spraying cleaning solution or disinfectant solution from the sterile water spray nozzles. As shown in Figure 1, sterile water produced by the sterile water production device 35 is supplied to each chamber through the sterile water supply pipe 36.

[0069] As mentioned above, although it varies depending on the chamber, spray nozzles are provided to inject cleaning solution, disinfectant solution, and sterile water into the chamber for cleaning and sterilization purposes, depending on the chamber's function. The spray nozzles are single-fluid nozzles, dual-fluid nozzles, rotating nozzles, etc., and the cleaning solution is sprayed when cleaning, and the disinfectant solution is sprayed when sterilization. If a liquid containing peracetic acid and hydrogen peroxide is used as the disinfectant solution for sterilization, the disinfectant solution is also a liquid, and the spray nozzle can be used for both. Furthermore, sterile water is also a liquid, and sterile water can also be sprayed into the chamber from the same liquid spray nozzle.

[0070] As shown in Figure 3, each chamber is equipped with an in-chamber injection nozzle 42 and an in-chamber rotating injection nozzle 43 for injecting cleaning solution, disinfectant solution, and sterile water, respectively. The in-chamber injection nozzle 42 and the in-chamber rotating injection nozzle 43 can inject liquids. Alternatively, a nozzle for injecting gas instead of liquid may be provided inside the chamber.

[0071] The chamber-in-chamber spray nozzle 42 uses either a single-fluid spray or a two-fluid spray that mixes a cleaning solution or disinfectant solution with compressed air and sprays it, so that the cleaning solution or disinfectant solution adheres to the entire area inside each chamber that needs cleaning or disinfecting. The chamber is cleaned or disinfected by the sprayed cleaning solution or disinfectant solution. The chamber-in-chamber spray nozzle 42 is positioned so that the cleaning solution or disinfectant solution adheres to the entire area inside the chamber.

[0072] The cleaning solution contains water and inorganic basic compounds such as sodium hydroxide and potassium hydroxide, or organic basic compounds such as ethanolamine and diethylamine. In addition, it contains alkali metal salts of organic acids, alkaline earth metal salts, ammonium salts, metal ion sequestering agents such as ethylenediaminetetraacetic acid, anionic surfactants, cationic surfactants, and polyoxyethylene alkylphenyl The solution may contain nonionic surfactants such as ethers, solubilizers such as sodium cumenesulfonate, acidic polymers such as polyacrylic acid or their metal salts, corrosion inhibitors, preservatives, antioxidants, dispersants, and defoamers. It may also be an acidic cleaning solution obtained by adding inorganic acids such as hydrochloric acid, nitric acid, and phosphoric acid, or organic acids such as acetic acid, formic acid, octanoic acid, oxalic acid, citric acid, succinic acid, and gluconic acid to water.

[0073] The disinfectant solution can be the same as the disinfectant used to sterilize the container, and it is preferable to use a disinfectant solution containing peracetic acid or hydrogen peroxide. The disinfectant solution may be sprayed multiple times using different solutions.

[0074] During operation of the aseptic filling machine, as shown in Figure 3, an aseptic air supply device 44 is provided in each chamber to maintain sterility in each chamber after the chamber has been sterilized. The aseptic air supply device 44 supplies air sterilized by a sterilization filter 46 from a blower 45 into each chamber. The air may also be heated by a heating device 47. The chamber-side surface of the sterilization filter 46 is sterilized by spraying it with a disinfectant solution. In addition, an exhaust device 48 may be provided at the bottom of the chamber to maintain the appropriate pressure inside the chamber.

[0075] When spraying cleaning solution, disinfectant solution, and sterile water into each chamber, for example, the cleaning solution is sprayed to clean, sterile water is sprayed to rinse off the cleaning solution, the disinfectant solution is sprayed to disinfect, and sterile water is sprayed to rinse off the disinfectant solution. When rinsing off the cleaning solution, it is not necessary to use sterile water because disinfection will be performed afterward. However, it is preferable to use sterile water to suppress contamination of the chamber by bacteria.

[0076] As shown in Figure 1, water is supplied from the water supply tank 33 to the sterile water production device 35, and the supplied water is sterilized by heating in the sterile water production device 35 to produce sterile water. The water is heated to at least 120°C for at least 4 minutes. The sterile water may be water that has been sterilized to a bactericidal value higher than the sterilization conditions of the contents to be filled. The heated and sterilized sterile water is sprayed into each chamber while still heated, without being cooled to room temperature. By raising the temperature above room temperature, the cleaning ability of the sterile water is improved. Preferably, by setting the temperature between 60°C and 100°C, the cleaning ability of the sterile water can be improved significantly.

[0077] The sterile water production apparatus 35 is a device that heats water from 20°C to 65°C in a first-stage heating section, which consists of multiple shell-and-tube heat exchangers connected in series, and then heats the water from 65°C to 140°C in a second-stage heating section, which consists of more shell-and-tube heat exchangers connected in series than the first-stage heating section. The water heated to 140°C is then held at 140°C in a holding tube for sterilization. The water is further cooled in a cooling section provided in the sterile water production apparatus 35. The sterile water is supplied in a heated state without being cooled to room temperature. Alternatively, the produced sterile water may be stored in a storage tank before being supplied to each chamber.

[0078] As shown in Figure 3, the heated sterile water sprayed into each chamber to rinse away the cleaning or disinfecting solution is recovered by the sterile water recovery device 49, passes through the sterile water recovery pipe 37, and is sent to the heat exchanger 34, where it is heat-exchanged with the water sent from the water supply tank 33 to the sterile water production device 35. The room temperature water is heated up from room temperature by the heat exchange with the recovered sterile water and is then sent to the sterile water production device 35.

[0079] As shown in Figure 3, the sterile water sprayed into each chamber is collected in a sterile water recovery channel 50 located at the bottom of the chamber, and then sent from the sterile water recovery channel 50 through a valve to a sterile water recovery pump 51 and into a sterile water recovery piping 37. The sterile water recovery device 49 comprises at least a sterile water recovery piping 37, a valve, and a sterile water recovery pump 51.

[0080] The heat exchanger 34 exchanges heat between the sterile water that has been supplied to each chamber and recovered, and the water supplied from the water supply tank 33. The water supplied from the water supply tank 33 is at room temperature, but the recovered sterile water is the sterile water supplied at 60°C to 100°C that has cooled down to 50°C to 90°C, and the room temperature water supplied from the water supply tank 33 can be heated to 30°C to 50°C. Since the energy supplied for heating in the heating section of the sterile water production device 35 can be reduced, energy is saved and CO2 emissions can be reduced.

[0081] The heat exchanger 34 has a heating capacity equivalent to that of the first-stage heating section of the sterile water production apparatus 35. Alternatively, the heat exchanger 34 may be incorporated into the sterile water production apparatus 35 as the first-stage heating section, or as a component of the first-stage heating section.

[0082] The collected and heat-exchanged sterile water is cooled to a temperature between 20°C and 40°C. The cooled sterile water is then discharged. Alternatively, instead of discharging it, it may be used to clean the washing device that washes the outer surface of the sealed container 2.

[0083] Before operating the sterile filling machine to fill the contents into container 2, a CIP (Clean-in-Place) and SIP (Sterilization) process is performed to clean and sterilize the contents supply piping, including the filling nozzle 41. Similar to cleaning or sterilizing the chamber, a cleaning solution or sterilizing solution is used. Sterile water is supplied to the contents supply piping to wash away the used cleaning solution or sterilizing solution. CIP or SIP is performed by receiving the cleaning solution or sterilizing solution at the filling nozzle and circulating it through the contents supply piping. In CIP or SIP, heat exchange between the sterile water used to wash away the cleaning solution or sterilizing solution and the water supplied to the sterile water production device is disclosed in Japanese Patent Application Publication No. 2021-35867. In this case, the heat exchange takes place at the water supply point, which is the inlet of an already formed circulation path, and the recovery of the sterile water used for washing is performed in the circulation path, eliminating the need to install a new recovery device. In this disclosure, a new recovery device is required to recover the sterile water used to wash away the cleaning solution or sterilizing solution used for cleaning or sterilizing the chamber. Comparing the area that needs to be washed with sterile water, the amount of sterile water used for cleaning or sterilizing the inside of a chamber is far greater than the amount of sterile water used for CIP or SIP, resulting in significant energy savings.

[0084] When the sterile filling machine is in operation, as shown in Figure 1, sterile water produced by the sterile water production device 35 is supplied to the rinse device chamber 20 via the sterile water supply pipe 36. The supplied sterile water is sprayed onto the sterilized container 2, as shown in Figure 2F-1 or Figure 2F-2. The sterile water sprayed onto the container 2 washes away any disinfectant and foreign matter adhering to the container 2.

[0085] As shown in Figure 4, the sterile water sprayed onto the container 2 in the rinsing chamber 20 is collected in a sterile water recovery channel 50 located at the bottom of the rinsing chamber 20, and then sent from the sterile water recovery channel 50 through a valve to the sterile water recovery piping 37 by a sterile water recovery pump 51. The sterile water recovery device 49 comprises at least a sterile water recovery piping 37, a valve, and a sterile water recovery pump 51.

[0086] To wash away the disinfectant adhering to the sterilized lid material 3, sterile water is supplied to the lid material sterilization device 31. The sterile water used to rinse the lid material 3 is collected in a sterile water recovery channel provided within the lid material sterilization device 31, recovered, and sent to the sterile water recovery pipe 37.

[0087] As shown in Figure 4, the sterile water supplied to the rinsing device chamber 20 to rinse the sterilized container 2 is recovered by the sterile water recovery device 49, passes through the sterile water recovery pipe 37, and is sent to the heat exchanger 34, where it is exchanged with the water sent from the water supply tank 33 to the sterile water production device 35. The water is exchanged. Room temperature water is heated by heat exchange with the recovered sterile water, causing it to rise in temperature before being sent to the sterile water production device 35. The recovered sterile water may also be stored in a tank and then sent to the heat exchange device 34.

[0088] The heat exchanger 34 may be supplied with sterile water used to rinse the sterilized container 2 and sterile water used to rinse the lid material 3. The recovered sterile water and the water supplied from the water supply tank 33 are heat-exchanged. The water supplied from the water supply tank 33 is at room temperature, but the recovered sterile water is sterile water supplied at 60°C to 100°C that has cooled down to 50°C to 90°C, and the room temperature water supplied from the water supply tank 33 can be heated to 30°C to 50°C. This reduces the energy supply required for heating in the heating section of the sterile water production device 35, resulting in energy savings and contributing to the reduction of CO2 emissions.

[0089] The recovered and heat-exchanged sterile water is cooled to a temperature of 20°C or higher and 40°C or lower. The cooled sterile water may be supplied to a washing device that washes the outer surface of the sealed container 2 and used to wash the outer surface of the sealed container 2.

[0090] In the examples, a method of sterilizing the container with hydrogen peroxide was described, but a peracetic acid rinse method or a bottle hot water rinse method may also be used. [Explanation of Symbols]

[0091] 1…Preform 1a...Mouth 1b...Support ring 2…Container 3…Lid material 17...Sterilizer 18… Sterilization device chamber 19… Rinse device 20... Rinse device chamber 21...Filling device 23… Filling device chamber 24...Sealing device 25... Sealing device chamber 28…Discharge device 29... Discharge device chamber 30... Discharge conveyor 31…Lid material sterilizer 33...Water supply tank 34...Heat exchange device 35...Sterile water production equipment 36...Sterile water supply piping 37... Sterile water recovery piping 40…Container washing nozzle 42...Injection nozzle inside the chamber 43...Rotating nozzle for injection inside the chamber 49... Sterile water recovery device 50... Sterile water collection channel 51…Sterile water recovery pump

Claims

1. The containers being transported are sterilized, The sterilized container is filled with the sterilized contents in a sterile atmosphere. In a sterile filling machine that seals the container filled with the contents in a sterile atmosphere with a sterilized lid, The parts that perform the sterilization, filling, and sealing are shielded by a chamber. The sterile water supplied to the rinsing device chamber to rinse the sterilized container is collected, A method for reusing sterile water, comprising supplying the recovered sterile water to a heat exchange device and exchanging heat with water before sterilization for producing the sterile water.

2. In the method for reusing sterile water according to claim 1, A method for reusing sterile water, which has been heat-exchanged, to clean the outer surface of a sealed container.

3. The containers being transported are sterilized, The sterilized container is filled with the sterilized contents in a sterile atmosphere. In a sterile filling machine that seals the container filled with the contents in a sterile atmosphere with a sterilized lid, The parts that perform the sterilization, filling, and sealing are shielded by a chamber. A method for reusing sterile water, wherein, before sterilizing each chamber, the chambers that are heavily contaminated due to the contents being scattered inside the chamber are cleaned by spraying them with hot water, boiling water, an alkaline cleaning solution mainly composed of caustic soda, or an acidic cleaning solution.

4. In the method for reusing sterile water according to claim 3, A method for reusing sterile water without cleaning the sterilization chamber that shields the sterilization device that sterilizes the aforementioned container before sterilization.

5. The containers being transported are sterilized, The sterilized container is filled with the sterilized contents in a sterile atmosphere. In a sterile filling machine that seals the container filled with the contents in a sterile atmosphere with a sterilized lid, The parts that perform the sterilization, filling, and sealing are shielded by a chamber. A method for reusing sterile water, comprising: cleaning and sterilizing the chamber before operating the sterile filling machine; spraying a cleaning solution to perform the cleaning; spraying non-sterile water to rinse away the cleaning solution; spraying a disinfecting solution to perform the sterilization; and spraying sterile water to rinse away the disinfecting solution.

6. In the method for reusing sterile water according to claim 5, To rinse away the cleaning solution used for the aforementioned cleaning, or to rinse away the disinfectant solution used for the aforementioned sterilization, heated sterile water sprayed into each chamber is collected. A method for reusing sterile water, comprising supplying the recovered sterile water to a heat exchange device and exchanging heat with water before sterilization for producing the sterile water.

7. In the method for reusing sterile water according to claim 1 or claim 6, A method for reusing sterile water, wherein the temperature of the sterile water supplied into the chamber is 60°C or higher and 100°C or lower.

8. Sterilization equipment for sterilizing containers being transported. A filling device that fills the container, which has been sterilized by the aforementioned sterilization device, with sterilized contents in a sterile atmosphere. A sealing device that seals the container filled with the contents in a sterile atmosphere with a sterilized lid material, A chamber that shields the sterilization device, the filling device, and the sealing device, A sterile water recovery device for recovering sterile water supplied to a rinsing device chamber for rinsing the sterilized container, A sterile filling machine for reusing sterile water, which includes a heat exchanger that exchanges heat between the sterile water recovered by the sterile water recovery device and the water used to produce the sterile water before sterilization.

9. In a sterile filling machine for reusing sterile water as described in claim 8, A sterile filling machine that reuses sterile water, configured to use the heat-exchanged sterile water for cleaning the outer surface of the sealed container.

10. In a sterile filling machine for reusing sterile water according to claim 8 or claim 9, A sterile filling machine for reusing sterile water, configured such that the temperature of the sterile water supplied into the chamber is between 60°C and 100°C.

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