Filling machine with sanitary chamber

Abstract

A filling machine (10) is provided that is configured to form, fill, and seal individual packages (4). The filling machine includes a sanitizing station (16) and a sanitizing chamber (20) downstream of the sanitizing station (16), the sanitizing chamber (20) configured to reduce the risk of recontamination of the packages after they have passed through the sanitizing station (16). An inner sanitizing zone (30) is formed within the sanitizing chamber (20), thereby establishing a positive air flow from the inner sanitizing zone (30) to the sanitizing chamber (20) outside the inner sanitizing zone (30).

Description

[Technical field]

[0001] The present invention relates to a filling machine, in particular to a filling machine configured to form, fill and seal individual packages. The present invention also relates to a method for such a filling machine. [Background technology]

[0002] In the food industry, beverages and other products are often packaged in paper or paperboard based packages. Packages intended for liquid foods are often manufactured from a packaging laminate comprising a core layer of paper or paperboard and an outer liquid-tight layer of thermoplastic material on at least that side of the core layer that forms the inside of the package.

[0003] One type of package that frequently appears is produced from so-called ready-to-fill packages. Such ready-to-fill packages are provided as a sleeve of packaging laminate as described above, whose bottom end is sealed before filling. The top end can be formed by sealing and forming the top end of the sleeve or by adding a top part, for example in the form of a plastic top, and the top / top part can be provided with an opening and closing means, such as a screw cap.

[0004] The open-ended packaging sleeve is received at an infeed station of the filling machine and then the bottom end is sealed. The semi-finished package has a shape ready for filling at this point, but further steps are required to provide a hygienic package. At a downstream station, the open sleeve is sterilized or disinfected, at least on the inside, to extend the shelf life of the product stored within the package. Different levels of sterilization / disinfection can be performed depending on the desired length of shelf life and whether the package will be distributed and stored in a refrigerated environment or at room temperature.

[0005] After sterilization / disinfection of the packages, the packages are further conveyed to a filling zone for product filling, a sealing zone for sealing of the open ends, and typically a final forming zone for final shaping of the package.

[0006] Conveyance of the packages is accomplished by a series of carriers guided along a conveying path, which is preferably continuous through the filling machine such that the stream of packages moves through the filling machine and all required stations.

[0007] After disinfection / sterilization of ready-to-fill packages, it is important to maintain hygienic conditions when the packages are filled and sealed by the associated stations. Therefore, these filling stations are installed in the hygiene zone to minimize recontamination of already disinfected or sterilized packages.

[0008] Complex mechanisms and geometries are required to properly fill, seal and convey packages within the hygienic zone. The structural components used in the fill-and-seal station (and associated stations for forming etc.) within the hygienic zone are subject to inspection and maintenance, and these stations must be accessed from time to time to allow high performance operation of the filling machine.

[0009] However, every access to the hygiene zone carries the risk of introducing unwanted particles or microorganisms from the outside, thereby increasing the risk of recontamination of the packaging.

[0010] As filling machines increase in speed and complexity to keep up with customer needs, the need for inspection and maintenance also increases, thereby requiring machine downtime and access to sanitation zones.

[0011] There is therefore a need for a filling machine that reduces the risk of recontamination of packages due to inspection and maintenance of parts located within the hygiene zone. Summary of the Invention [Problem to be solved by the invention]

[0012] It is an object of the present invention to at least partially overcome one or more of the above identified limitations of the prior art, in particular to provide a hygienic zone of a filling machine which reduces the risk of re-contamination of packages present within the hygienic zone. [Means for solving the problem]

[0013] To solve these objects, a filling machine is provided, configured to form, fill and seal individual packages, whereby the filling machine comprises a sterilization station and a sanitary chamber downstream of the sterilization station, the sanitary chamber being configured to reduce the risk of recontamination of the packages after passing through the sterilization station. An inner sanitary zone is provided inside the sanitary chamber, whereby a positive air flow is established from the inner sanitary zone to the sanitary chamber outside the inner sanitary zone.

[0014] The inner hygiene zone may be formed by a number of separator plates, at least one of which is movable to open and provide access to the inner hygiene zone.

[0015] The separator plates may extend from the ceiling to the floor, leaving a slit between the lower end of each separator plate and the floor.

[0016] The separators may be arranged in a U-shape, such that at least two longitudinal separators extend in the machine direction and at least one transverse separator extends perpendicular to the machine direction and connects the two longitudinal separators.

[0017] At least one of the separator plates may be movable to increase or decrease the size of the inner hygiene zone.

[0018] The inner hygiene zone may open to an upstream disinfection station.

[0019] The inner hygiene zone may comprise a filtered air unit. The filtered air unit may be located in a ceiling of the inner hygiene zone. The filtered air unit is a high efficiency particulate absorbing (HEPA) filter unit.

[0020] The positive airflow from the inner sanitary zone may be controlled by controlling the airflow of the filtered air unit.

[0021] The hygiene chamber may comprise an air exhaust unit arranged outside the inner hygiene zone. The air exhaust unit may be arranged in the ceiling of the hygiene chamber.

[0022] According to a second aspect, there is provided a method for a filling machine configured to form, fill and seal individual packages. The filling machine comprises a sanitization station and a sanitary chamber downstream of the sanitization station, the sanitary chamber configured to reduce the risk of recontamination of the packages after passing through the sanitization station. The method includes the steps of providing an inner sanitary zone inside the sanitary chamber and establishing a positive air flow from the inner sanitary zone to the sanitary chamber outside the inner sanitary zone.

[0023] Further objects, features, aspects and advantages of the present invention will become apparent from the following detailed description and drawings.

[0024] Embodiments of the invention will now be described, by way of example, with reference to the accompanying schematic drawings, in which: [Brief description of the drawings]

[0025] [Figure 1] FIG. 1 is a schematic diagram of a filling machine according to one embodiment. [Diagram 2] FIG. 2 is a top view of a filling machine according to one embodiment. [Diagram 3] 1 is a cross-sectional view of a filling machine according to one embodiment. [Figure 4] 1 is a schematic diagram of a method according to one embodiment. [Figure 5a-c] 1 is a graph showing a simulation of a filling machine being subjected to contamination during operation according to one embodiment; [Figure 6a-c] 13 is a graph of a simulation of pressure in a filling machine according to one embodiment during operation. [Figure 7] 13 is a graph showing a simulation of airflow during operation of a filling machine according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Referring to Figure 1, a filling machine 10 is shown diagrammatically. The filling machine 10, which is configured to form, fill and seal packages 4, has an infeed station 12 at which blanks 2 of packaging material are received. The blanks 2 are typically manufactured as sleeves of carton-based packaging material, as is well known in the art and has been briefly described above in the background section. The infeed station 12 is located upstream of a bottom sealing station 14, at which the blanks 2 are erected in a sleeve shape and the lower ends of each blank are sealed to form a semi-finished package which is closed at one lower end but still has an open upper end.

[0027] The semi-finished packages are conveyed to a sterilization station 16 where the amount of live microorganisms is reduced. As explained in the background section, the level of sterilization may vary depending on the user's objectives. Sterilization of the packaging material may be achieved, for example, by treatment with hydrogen peroxide, UV light, electron beam irradiation, etc. At the end of the filling machine, an output station 18 is arranged which is configured to release the finished packages 4 from the filling machine 10 to downstream equipment, storage, and / or transportation.

[0028] Between the sterilization station 16 and the delivery station 18, a sanitation chamber 20 is provided. The sanitation chamber 20 comprises a further station of the filling machine, a filling station 22 is arranged immediately downstream of the sterilization station 16. Here, the ready-to-fill packages are filled with the desired contents. After filling, the packages can be conveyed to a pre-folding station 24, where the top of the open-end package is formed into the desired shape. After pre-forming, the packages are conveyed to a heating station 26, where the heat-sealable material of the packaging material is heated to an elevated temperature. The elevated temperature of the top end of the package facilitates sealing of the top end when the package enters a sealing station 28 arranged immediately behind the heating station 26.

[0029] Once sealed, the packages 4 no longer require sanitary conditions, so they exit the sanitary chamber 20 and are discharged by the delivery station 18 (as previously described).

[0030] It should be understood that the sanitation chamber 20 may include more or fewer filler stations, so long as it provides sanitary conditions for the ready-to-fill packages, at least for a period of time after the ready-to-fill packages have been disinfected or sterilized. It should also be noted that the filler 10 need not be configured exactly as described with reference to Figure 1, and that the filler 10 may be configured to produce other types of packages, such as plastic top packages, etc.

[0031] In Figure 2, one embodiment of the filling machine 10 is shown in further detail, particularly with respect to the sanitary chamber 20. The filling machine stations, i.e., infeed station 12, bottom seal station 14, sanitary station 16, etc., are all shown in dashed lines and given the same reference numerals as in Figure 1. Also shown in Figure 2 is a transport path 50, which represents the conveyors and carriers used to transport packages from the infeed station 12 to the outfeed station 18 in the direction indicated by arrow A.

[0032] The sanitation chamber 20 covers the entire space of the filling machine 10 from the sterilization station 16 to the downstream location where the packages are completely sealed, which in the illustrated filling machine 10 occurs after the top sealing station 28 .

[0033] An inner hygiene zone 30 is defined within the hygiene chamber 20. The inner hygiene zone 30 forms a space within the hygiene chamber 20 and extends essentially the entire length of the hygiene chamber 20, but only a portion of the width of the hygiene chamber 20. As shown in FIG. 2, the inner hygiene zone 30 is formed by at least three walls 32, 34, 36. The first wall 32 extends from the outfeed end of the sterilization station 16 to one side of the transport path 50 in the machine direction across the filling station 22, the preforming station 24, the preheating station 26, and the top sealing station 28. The second wall 36 is disposed parallel to the first wall 32. The second wall 36 extends from the outfeed end of the sterilization station 16 to the opposite side of the transport path 50 in the machine direction across the filling station 22, the preforming station 24, the preheating station 26, and the top sealing station 28.

[0034] At the downstream end of the inner sanitary zone 30, a third wall 34 is disposed in a direction perpendicular to the direction of the first and second walls 32, 36. The third wall 34 therefore connects the first and second walls 32, 36 and forms an exit wall for packages 4 exiting the inner sanitary zone 30. From this it should be clear that the third wall 34 comprises some opening to allow packages to exit the inner sanitary zone 30.

[0035] The walls 32, 34, 36, which may total more than three, delimit a U-shaped space that protects the sanitized packages from the outside environment, as described further below. More specifically, the walls 32, 34, 36 of the inner sanitary zone 30 form a barrier when the filling machine 10 is accessed for inspection and maintenance.

[0036] The filling machine 10 has a housing 60 which forms the outer shell of the filling machine. One or more doors 62, 64 are provided in the housing 60 to allow staff to enter the interior of the filling machine to inspect the equipment and to carry out various operations on the filling machine 10. Typically, the doors 62, 64 can be located not only at the infeed station 12 but also at the top sealing station 28. In particular at the top sealing station 28 which is located inside the sanitary chamber 20, it is desirable to maintain as sanitary conditions as possible. The provision of an inner sanitary zone 20 which is separated from the rest of the sanitary chamber 20 allows staff to enter the sanitary chamber 20 via the door 64 without exposing the packages 4 present in the inner sanitary zone 30 to an increased risk of recontamination.

[0037] Preferably, as many mechanical parts as possible are located outside the inner sanitary zone 30 to allow inspection and maintenance without the need to enter the inner sanitary zone 30 .

[0038] The walls 32, 34, 36 of the inner sanitary zone 30 are preferably movable relative to the machine housing 60 so as to allow adjustment of the size of the inner sanitary zone 30. To this end, the first and second walls 32, 36 may be movable transverse to the machine direction, while the third wall 34 may be expandable so as to allow a closure to be formed between the first and second walls 32, 36.

[0039] It is also preferred that at least one of the walls 32, 34, 36 of the inner hygiene zone 30 is openable, for example by a sliding door mechanism, so that the inner hygiene zone 30 can be accessed for inspection and maintenance. Such an opening may preferably be equipped with a sensor that provides a signal when the inner hygiene chamber is opened. It is thus possible to monitor whether and when the inner hygiene zone 30 has been accessed.

[0040] 2, the inner hygiene zone 30 may include a partition wall 38, which is disposed between the filling station 22 and the pre-heat station 24. The purpose of the partition wall 38 is to provide a thermal barrier to the filling station 22 to prevent excess heat from the pre-heat station 24 from heating the filling station 22. The partition wall 38 (which may have some openings to allow packages to pass through) is advantageous, especially when chilled products are being filled.

[0041] Turning now to Fig. 3, a schematic view of the hygiene chamber 20 is shown in cross section. The inner hygiene zone 30 extends laterally between two walls 32, 36. Inside the inner hygiene zone 30, a conveying path 50 is arranged, which is represented here only diagrammatically by a simple shape. The separating wall 32, 36 extends downwards from the ceiling, leaving a slit 42 between its lower end and the floor. This slit 42 is provided to ensure a positive air flow from the inner hygiene zone 30 to the outer hygiene chamber 20.

[0042] The ceiling of the inner hygiene zone 30 is provided with an air filter unit 38, preferably in the form of a HEPA filter. The HEPA filter 38 ensures a positive downward flow of clean, filtered air. The air flow is directed towards the floor, as shown by the arrows, and is forced out of the inner hygiene zone 30 through slits 42. The air is finally exhausted by an air exhaust unit 40, located in the ceiling of the hygiene chamber 20 but outside the inner hygiene zone 30.

[0043] Turning now to Figure 4, a method 100 for a filling machine 10 is shown in schematic form. As previously explained, the filling machine 10 is configured to form, fill and seal individual packages 4, whereby the filling machine comprises a sterilization station 16 and a sanitary chamber 20 downstream of the sterilization station 16, the sanitary chamber 20 being configured to reduce the risk of recontamination of the packages after passing through the sterilization station 16. The method 100 comprises a first step 102 of providing an inner sanitary zone 30 inside the sanitary chamber 20, and a second step 104 of establishing a positive air flow from the inner sanitary zone 30 to the sanitary chamber 20 outside the inner sanitary zone 30.

[0044] Turning now to Figures 5a-c, there is shown the filling machine 10 during a simulation in which gas representing potential contamination is emitted from the entire bottom surface of the sterilization station 16 and the entire bottom surface of the sanitary chamber 20. As can be seen in Figure 5a, which is a cross-sectional side view of the filling machine 10, the concentration of contaminating gas is substantially less in the inner sanitary zone 30, which is further evident from Figure 5b, which is a cross-sectional top view of the filling machine 10. From the cross-sectional view of Figure 5c (same view as Figure 3), it can be seen that the inner sanitary zone 30 is substantially free of contaminating gas.

[0045] In Figures 6a-c the pressure distribution is shown during operation of the filling machine 10. These views are of the same cross section as for Figures 5a-c and show that in the region where the inner sanitary zone 30 opens into the outer sanitary chamber 20 a small but distinct pressure gradient occurs.

[0046] 7 is another cross-sectional view of the filling station 22, showing the airflow through the inner sanitary zone 30. The HEPA filters 38 provide a uniform downward flow of clean air.

[0047] Within the sanitary zone 30, a cool environment is established in the filling area, thereby minimizing microbial growth within the filling station 22. This cool environment is ensured by a partition wall 38, shown in FIG.

[0048] As mentioned above, the presented solution helps to prevent recontamination of the sanitary chamber 20 both during production mode and during production shutdowns.

[0049] A small but well-defined pressure gradient is established between the inner sanitary zone 30 and the outer sanitary chamber 20, providing robust protection of the critical inner sanitary zone 30. Furthermore, it also prevents contamination from the cassette / conveyor / carryway 50 in critical areas.

[0050] During production stops where access to the sanitary chamber 20 is required, the risk of causing contamination when opening the large doors 62, 64 to the sanitary chamber 20 is reduced, since the small separation walls 32, 34, 36 only open a relatively small area when access is required. Additional benefits of the proposed concept include a simplified supply system design, since the exhaust system can be located above the ceiling of the sanitary chamber, with the separation walls 32, 34, 36 preventing splashing of the exhaust system design. Furthermore, a more efficient utilization of the HEPA filters is achieved, thereby reducing the flow rate requirements.

[0051] From the foregoing description, while various embodiments of the present invention have been described and illustrated, the present invention is not limited thereto and may be embodied in other ways within the scope of the subject matter defined in the following claims.

Claims

1. 1. A filling machine (10) configured for forming, filling and sealing individual packages (4), comprising a sterilization station (16) and a sanitary chamber (20) downstream of said sterilization station (16), said sanitary chamber (20) configured to reduce a risk of re-contamination of said packages after passing said sterilization station (16), said filling machine further comprising an inner sanitary zone (30) within said sanitary chamber (20), said inner sanitary zone (30) establishing a positive air flow from said inner sanitary zone (30) to said sanitary chamber (20) outside said inner sanitary zone (30), the inner hygiene zone (30) is formed by a plurality of separation plates (32, 34, 36), at least one of which is movable to open and provide access to the inner hygiene zone (30); the separators (32, 34, 36) are arranged in a U-shape, such that at least two longitudinal separators (32, 36) extend in the machine direction and at least one transverse separator (34) extends perpendicular to said machine direction and connects said two longitudinal separators (32, 36); the inner sanitary zone (30) defines a space inside the sanitary chamber (20) and extends over the entire length of the sanitary chamber (20) but only over a portion of the width of the sanitary chamber (20); Filling machine (10).

2. 2. The filling machine of claim 1, wherein said separator plates (32, 34, 36) extend from the ceiling toward the floor, leaving a slit (42) between a lower end of each separator plate (32, 34, 36) and said floor.

3. 3. The filling machine of claim 1 or 2, wherein at least one of the separator plates (32, 34, 36) is movable to increase or decrease the size of the inner hygiene zone (30).

4. The filling machine according to any one of claims 1 to 3, wherein the inner hygiene zone (30) opens towards the upstream disinfection station (16).

5. The filling machine according to any one of the preceding claims, wherein the inner hygiene zone (30) comprises a filtered air unit (38).

6. The filling machine of claim 5, wherein the filtered air unit (38) is disposed in a ceiling of the inner sanitary zone (30).

7. 7. The filling machine of claim 5 or 6, wherein the positive air flow from the inner sanitary zone (30) is controlled by controlling the air flow of the filtered air unit (38).

8. The filling machine of any one of claims 5 to 7, wherein the filtered air unit (38) is a HEPA filter unit.

9. The filling machine according to any one of the preceding claims, wherein the sanitary chamber (20) comprises an air evacuation unit (40) arranged outside the inner sanitary zone (30).

10. 10. The filling machine according to claim 9, wherein the air exhaust unit (40) is arranged in the ceiling of the sanitary chamber (20).

11. A method for a filling machine configured to form, fill and seal individual packages (4), said filling machine comprising a sterilization station (16) and a sanitary chamber (20) downstream of said sterilization station (16), said sanitary chamber (20) configured to reduce the risk of re-contamination of the packages after passing through said sterilization station (16), said method comprising: providing an inner sanitary zone (30) inside the sanitary chamber (20); and establishing a positive air flow from the inner sanitary zone (30) to the sanitary chamber (20) outside the inner sanitary zone (30), the inner sanitary zone (30) defines a space inside the sanitary chamber (20) and extends over the entire length of the sanitary chamber (20) but only over a portion of the width of the sanitary chamber (20); method.

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