Method and system for removing excess sterilant from a web of carton-based packaging material - Patents.com

Abstract

An apparatus (312) is presented for removing excess sterilant (308) from a web (102) of carton-based packaging material, the web (102) including a number of consecutively arranged sections (200a-200f) arranged to form a package (112), each section of the web (102) including an opening device (202a-f) attached thereto, and at least a subset of the sections (200a-f) including positioning elements (204a-f). The apparatus (312) includes a positioning element reader (314) configured to determine the positions of positioning elements (204a-f) included on or on the web (102), a control unit (316) configured to estimate the positions of the opening devices (202a-f) based on the positions of the positioning elements (204a-d), and an air pulse device (318) configured to provide air pulses (320a-b), the control unit (316) further configured to adjust the air pulse device (318) based on the position of the opening device, the air pulses (320a-b) being provided to the opening device regions (210a-f) of the web (102) to remove the sterilant (308) from the opening devices (202a-f).

Description

[Technical field]

[0001] The present invention relates generally to the field of packaging technology, such as food packaging technology. More particularly, the present invention presents a method and apparatus for removing excess sanitizing agent from a web of packaging material. [Background technology]

[0002] It is currently commonly known to use roll-fed packaging machines for different types of food products (e.g., milk). Roll-fed packaging machines, also called fillers, have several advantages. One advantage is that the continuous production of packages can be achieved at a higher rate compared to empty-fed packaging systems. Another advantage is that by continuously filling a tube of packaging material to form a package at the bottom end of the tube, the risk of unwanted microorganisms entering the package can be reduced.

[0003] To ensure that the packaging material is free of undesirable microorganisms, it can be fed into a sterilization bath. The sterilization bath contains only a sterilizing agent or a mixture of a sterilizing agent and a wetting agent. In this text, for ease of understanding, the liquid in the bath is named as sterilizing agent, whether it is with a wetting agent as a mixture or not. A drawback with sterilizing baths is the need to remove the sterilizing agent used in the sterilizing bath to prevent this or these sterilizing agents from ending up on the produce. One way to remove the sterilizing agent is to dry the packaging material using heated sterilizing air.

[0004] Currently, technology exists to ensure adequate removal of biocides, but there is still a need to improve the technology so that this biocide removal can be achieved more efficiently, for example in terms of energy use. Summary of the Invention [Problem to be solved by the invention]

[0005] It is an object of the present invention to at least partially overcome one or more of the above-mentioned limitations of the prior art, in particular to provide an apparatus for removing excess sterilant from packaging materials by using air pulses. [Means for solving the problem]

[0006] According to a first aspect, there is provided an apparatus for removing excess sanitizer from a web of carton-based packaging material, the web comprising a number of successively arranged sections arranged to form a package, each section of the web comprising an opening device mounted to the successively arranged sections, at least a subset of the sections comprising a positioning element. The apparatus comprises: a positioning element reader arranged to determine the location of a positioning element contained on or on the web; a control unit configured to estimate a position of the opening device based on a position of the positioning element; an air pulse device configured to provide an air pulse; Including, The control unit is further configured to adjust the air pulse device based on a position of the opening device, where the air pulses are delivered to the opening device area of ​​the web to remove excess sterilant from the opening device.

[0007] The aperture device may be an injection molding aperture device that perforates the web.

[0008] The air pulse devices may be positioned to provide air pulses on both sides of the web.

[0009] The air pulse device may include an air pulse pump arranged to increase an air pulse pressure between successive air pulses, and an air pulse valve configured to release the air pulse pressure to form an air pulse.

[0010] The air pulse valve may be a radial valve or a solenoid valve.

[0011] The air pulse pressure when the air pulse valve is opened may be between 1.5 and 5.0 bar, preferably 2.0 bar.

[0012] The disinfectant may include hydrogen peroxide.

[0013] The air pulse device may be configured to deliver between 3 and 10 air pulses per second.

[0014] The positioning elements may be magnetic marks integrated into the web.

[0015] According to a second aspect, there is provided a packaging system comprising: a packaging material receiver positioned to receive the web of packaging material; an opening device feeder arranged to feed an opening device to the web; a sterilizing bath arranged to supply a sterilizing agent to the web; An apparatus according to the first aspect (any one of claims 1 to 8) arranged to remove excess disinfectant from the aperture device area of ​​the web; a sterilization chamber for sterilizing the web; A sterile room where packages are formed from webs Includes.

[0016] The opening device supplier may be an injection molding apparatus arranged to supply an injection molding opening device for perforating the web.

[0017] According to a third aspect, there is provided a method of removing excess sanitizer from a web of carton-based packaging material, the web comprising a number of successively arranged sections arranged to form a package, each section of the web comprising an opening device attached to the successively arranged sections, at least a subset of the sections comprising a positioning element. The method comprises: determining a location of a positioning element in or on the web; estimating a position of the opening device based on the positioning element; adjusting the air pulse device based on the position of the aperture device; providing air pulses to the web in the area of ​​the aperture device to remove excess sterilant from the aperture device; Includes.

[0018] The aperture device may be an injection molding aperture device that perforates the web.

[0019] The method may further include the step of supplying a sterilizing agent to the web by supplying the web through a sterilizing bath prior to the step of determining the position of the positioning element.

[0020] The method may further include increasing the air pulse pressure by using an air pulse pressure pump; The step of providing an air pulse pressure is performed by opening an air pulse pressure valve to form an air pulse.

[0021] Further objects, features, aspects and advantages of the present invention will become apparent from the following detailed description and drawings.

[0022] Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0023] [Figure 1] 1 is a typical example of a roll-fed packaging material. [Figure 2a-d] 10 illustrates different examples of how a web of packaging material can be positioned. [Diagram 3] 1 illustrates a schematic diagram of a packaging system; [Figure 4] 1 is a flow chart illustrating a method of removing excess sterilant from a web of carton-based packaging material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] With reference to Figure 1, a packaging machine 100, also called a filling machine, is shown by way of example in general terms. The packaging machine 100 is a roll-fed packaging machine used for packaging liquid food products in carton-based packages. Already in the 1940s, this type of packaging machine was introduced by Tetra Pak and is now a well-known method of packaging milk and other liquid food products in a safe and cost-effective manner. Furthermore, the general method can be used for non-liquid food products such as potato chips.

[0025] Currently, packaging materials are often printed and prepared at packaging production centers, also known as converting plants, and shipped to a site, e.g., a dairy, where a packaging machine 100 is located. Typically, before the packaging material is transported, it is loaded onto a reel. Once at the site, the reel is placed into the packaging machine, as illustrated in FIG.

[0026] During production, a web 102 of packaging material can be fed from a reel through a packaging machine in a web feed direction A. Although not illustrated in FIG. 1, the packaging material can pass through a sterilization device, such as a hydrogen peroxide bath or an LVEB (low voltage electron beam) station, to ensure that the web 102 is free of undesirable microorganisms. A tube can be formed from the web 102 by forming a longitudinal seal before feeding the food product. The food product can be fed into the tube via a pipe 104, and a valve 106 can be used to regulate the flow through the pipe 104. A lower end 108 of the tube can be fed into a folding device 110 that forms a transverse seal, and cuts the tube so that the tube can be folded according to fold lines, also called lines of weakness, to form a package 112. Although the folding device 110 is illustrated as one single device, the folding device 110 can include many different devices.

[0027] 2a-2d, a web 102 of carton-based packaging material is shown by way of example. The web 102 may include a number of consecutively arranged sections 200a-f. Each of the number of consecutively arranged sections 200a-f may include an opening device 202a-f attached thereto. At least a subset of the number of consecutively arranged sections 200a-f may include positioning elements 204a-f.

[0028] 2a and 2b, each of the multiple consecutively arranged sections 200a-f may include multiple fold lines 206a-f. The multiple fold lines 206a-f may be based on what type of package 112 the web 102 is to be folded into. Furthermore, each of the multiple consecutively arranged sections 200a-f may include a lateral seal and a longitudinal seal. The lateral seals may be arranged to form a top and bottom of the folded package, while the longitudinal seals may be arranged to seal the folded package along the sides.

[0029] As an example, as illustrated in Figures 2c and 2d, a number of consecutively arranged sections 200a-f may include only horizontal and vertical seals and may not include a number of fold lines 206a-f, with fold lines set in this manner causing the resulting package 112 to have a bag-like appearance instead of the brick-shaped appearance of the package 112 formed by the web 102 illustrated in Figures 2a and 2b.

[0030] The opening devices 202a-f may be arranged to provide an easy opening that can be used after the web 102 is formed into the package 112. The opening devices 202a-f may be arranged to provide a predetermined method of opening the package 112. The opening devices 202a-f may be injection molded opening devices that can perforate the web 102. The advantage of using this type of opening, also called micro injection molded opening, is that the amount of plastic used can be reduced compared to jet and screw cap based opening devices.

[0031] The positioning elements 204a-f may be included in or on the web 102. The positioning elements 204a-f, which may be, for example, magnetic marks, may be integrated into the packaging material such that the position of the positioning elements, referred to herein as information carriers, remains during production. Alternatively, as an example, the positioning elements 204a-f may be provided on the packaging material as optical reference marks (e.g. printed marks provided on the packaging material).

[0032] In this situation, the positioning elements 204a-f may be used to provide the packaging machine with a reference position on the web 102. In other words, the positioning elements 204a-f may be used to provide the packaging machine with information regarding the position of the web. The positioning elements 204a-f may be marks and / or codes that can be read by a photocell, a camera, or a tape reader. Optionally, as described above, the positioning elements 204a-f may be information carriers. The positioning elements 204a-f may be any reference position that provides information regarding the position of the web, but are not limited to any of these examples. According to one example, the opening devices 202a-f themselves may be positioned to serve as visual reference points as well. As illustrated in Figures 2a and 2c, each of the many consecutively arranged sections 200a-f may include a positioning element 204a-f. With this setup, the position of the opening devices 202a-f may be determined based on the position of the positioning elements 204a-f placed in the same section. However, it is not necessary to place the positioning elements 204a-f and the opening devices 202a-f in the same section. As illustrated in Fig. 2b and Fig. 2d, the positioning elements 204a-f may be provided only in a subset of the sections 200a-f. The accuracy of determining the position of the opening devices 202a-f may be lower than in the example illustrated in Fig. 2a and Fig. 2c. However, since fewer positioning elements 204a-f are used, the production cost of the packaging material can be reduced. In other words, one of the positioning elements 204a-f may be used to estimate the position of multiple opening devices 202a-f.

[0033] 3, an example packaging system 300 is shown. The packaging system 300 may include a packaging material receiver 302, an opening device supplier 304, a sterilization bath 306, an apparatus 312, a sterilization chamber 326, and a sterile room 328.

[0034] A packaging system 300 may be arranged to form packages 112 from a web 102 of carton-based packaging material. The web 102 may be fed to the packaging system 300 via a packaging material receiver 302. The web 102 may then be fed to an opening device feeder 304. The opening device feeder 304 may be arranged to feed opening devices 202a-f to the web 102, for example by using an injection molding apparatus. It may be arranged to feed injection molded opening devices that perforate the web 102. This may be made possible by having perforations in the carton layer of the web 102, i.e., by having weakened sections of the web to allow molten plastic to be forced through.

[0035] To sterilize the web 102, the web 102 may be fed into a sterilizing bath 306. The sterilizing bath 306 may be arranged to feed a sterilizing agent 308 to the web 102. The sterilizing agent 308 may be arranged to ensure that bacteria and other undesirable microorganisms are removed from the packaging material. According to one example, the sterilizing agent 308 may include hydrogen peroxide. Rollers 310a,b may be used to remove excess sterilizing agent 308 and / or spread the sterilizing agent across the web.

[0036] Having the opening devices 202a-f applied to the web 102 may make it more difficult to remove the sterilant 308. In other words, the opening devices 202a-f on the web 102 may impart protrusions onto the web 102 such that excess sterilant 308 may remain in or near the opening devices 202a-f.

[0037] Here, "excess" may mean any amount of sterilant present on or near the opening devices 202a-f that exceeds a predetermined sterilant layer thickness. This predetermined thickness may be a thickness value imparted by the rollers 310a,b. For example, this predetermined thickness may be a value between 1-5 mm, more preferably between 1-2 mm. This excess amount may be removed by blowing an air pulse at a predetermined pressure, as described below, at a predetermined location controlled by the positioning elements 204a-f and the positioning element reader 314.

[0038] Here, "removing" may mean moving the excess amount of sterilant from the opening devices 210a-f elsewhere, which may be the web 102 around the opening devices 210a-f. The excess sterilant may be removed in the sterilization chamber 326, as described below.

[0039] To remove excess sterilant 308 retained in the opening devices 202a-f, the apparatus 312 may include a positioning element reader 314, a control unit 316, and an air pulse device 318. The positioning element reader 314 may be positioned to determine the position of the positioning elements 204a-f, which may be included in or on the web 102, as described above.

[0040] The control unit 316 may be arranged to estimate the positions of the opening devices 202a-f based on the positions of the positioning elements 204a-f. How to relate the positions of the positioning elements 202a-f to the positions of the opening devices 202a-f may be known based on information from a packaging material production centre.

[0041] The air pulsing device 318 may be positioned to provide air pulses 320a-b to remove excess sanitizing agent. The air pulses 320a-b may be provided towards the web 102. The air pulsing device 318 may be positioned to provide 3-10 air pulses 320a-b per second. According to the example shown in FIG. 3, the air pulsing device 318 may be positioned to provide air pulses 320a-b on both sides of the web 102. Alternatively, the air pulsing device 318 may be positioned to only provide air pulses 320a-b on one side of the web 102. In the case of one sided delivery, it is preferred to provide air pulses 320a-b on the inside of the web 102 since this is the side that contacts milk and other liquid food products.

[0042] The control unit 316 may be arranged to adjust the air pulse device 318 based on the position of the opening devices 202a-b, which may be determined based on the position of the positioning elements 202a-f as described above. The air pulses 320a-b may be provided to the opening device areas 210a-f of the web 102 on which the opening devices are placed. The opening device areas 210a-f may be larger than the areas of the opening devices 202a-f to cover the opening devices 202a-f and the surrounding areas.

[0043] The air pulse device 318 may include an air pulse pressure pump 322. The air pulse pressure pump 322 may be arranged to increase the air pulse pressure between successive air pulses 320a-b. The air pulse device 318 may include air pulse pressure valves 324a-b. The air pulse pressure valves 324a-b may be arranged to release the air pulse pressure to form the air pulses 320a-b. The length of the air pulses 320a-b may be altered due to the length of the opening of the air pulse pressure valves 324a-b. The air pulse pressure valves 324a-b may be radial or solenoid valves. The air pulses 320a-b may be highly pressurized air pulses. When the air pulse pressure valves 324a-b are opened, the air pulse pressure may be 1.5-5.0 bar, preferably 2.0±0.1 bar. The control unit 316 may be arranged to control the air pulse pressure pump 322 and the air pulse pressure valves 324a-b. More specifically, the control unit 316 may be arranged to open the air pulse pressure valves 324a-b when the opening devices 202a-f pass the air pulse device 318.

[0044] Highly pressurized air may be generated by using pulses of air instead of a continuous supply of pressurized air. Thus, instead of a continuous supply of air flow, pulses of air are used in areas where excess sterilant is likely to be found, such as opening device areas 210a-f.

[0045] The use of air pulses instead of air streams is further beneficial from an energy efficiency standpoint. By identifying specific areas of interest, e.g., opening device regions 210a-f, and providing air pulses to these areas, less energy may be required than providing a continuous air stream. Furthermore, air pulses prove beneficial from a sterilization performance standpoint. By simply removing excess sterilant in the opening device regions 210a-f, other areas of the web 102 may be left untouched, with the effect of improving sterilization in these other areas.

[0046] As the web 102 passes through the apparatus 312, it may be fed into a sterilization chamber 326. The sterilization chamber 326 may be arranged to sterilize the web 102. To do so, hot air may be fed to the web 102 and the opening devices 210a-f to evaporate sterilizing agents present in the web 102 and the opening devices 210a-f. The web 102 may then be fed into a sterilization chamber 328, where packages are formed with the web 102.

[0047] As mentioned above, by using the present system, less energy is required since it uses air pulses instead of a continuous air flow. By using air pulses instead of a continuous air flow, the total air flow rate is much less since air is only required for the small area where the injection mold opening is located. This is a more efficient solution to remove excess sterilant when the injection mold opening is on the package compared to using a continuous air flow.

[0048] Another advantage gained is that the system does not impede sterilization of the packaging material because only air is directed to a small portion of the web. Furthermore, because only air is directed to a small portion of the web, the air does not heat the packaging material and reduce the effectiveness of the sterilization.

[0049] 4 presents, by way of example, a flow chart illustrating a method 400 of removing excess sterilant 308 from a web 102 of carton-based packaging material. The web 102 may include a number of consecutively arranged sections 200a-f, which may be arranged to form a package 112. Each section of the web 102 may include an opening device 202a-f mountable thereto, and at least a subset of the sections 200a-f may include positioning elements 204a-f.

[0050] In a first step 402, the positions of the positioning elements 204a-f can be determined. The positioning elements 204a-f can be included in or on the web 102. In a second step 404, the positions of the opening devices 202a-f can be estimated based on the positions of the positioning elements 204a-f. In a third step 406, the air pulse device 318 can be adjusted based on the positions of the opening devices 202a-f. The opening devices 202a-f can be injection molded opening devices that can perforate the web 102. In a fourth step 408, air pulses 320a-b can be provided to the opening device regions 210a-f of the web 102 so that excess sterilant 308 can be removed from the opening devices 202a-f.

[0051] Optionally, in a fifth step 410, prior to the step 402 of determining the positions of the positioning elements 204a-f, a sterilizing agent 308 can be applied to the web 102 by passing the web 102 through a sterilizing bath 306.

[0052] Optionally, in a sixth step 412, the air pulse pressure can be increased by using an air pulse pressure pump 322, and step 408 of supplying an air pulse pressure can be performed by opening air pressure valves 324a-b so that air pulses 320a-b can be formed.

[0053] Although listed in a particular order, it is not intended that the steps must be performed in that order.

[0054] From the above, although various embodiments of the present invention have been described and shown, the present invention is not limited to these embodiments, and the present invention may be embodied in other ways within the scope of the subject matter defined in the following claims.

Claims

1. An apparatus (312) for removing excess sterilant (308) from a web (102) of carton-based packaging material, said web (102) comprising a plurality of successively arranged sections (200a-200f) arranged to form a package (112), each section of said web (102) comprising an opening device (202a-f) attached thereto, at least a subset of said sections (200a-f) comprising a positioning element (204af); By excess germicide (308) is meant any amount of germicide present on a surface on the opening device (202a-f) that exceeds a predetermined germicide layer thickness; The apparatus comprises: a positioning element reader (314) included in or arranged to determine the location of the positioning elements (204a-f) on the web (102); a control unit (316) configured to estimate a position of the opening device (202a-f) based on the positions of the positioning elements (204a-d); an air pulse device (318) arranged to provide air pulses (320a-b); Including, the control unit (316) is further configured to adjust the air pulse device (318) based on the position of the opening device, the air pulses (320a-b) being delivered to the opening device regions (210a-f) of the web (102) to remove excess of the sterilant (308) from the opening devices (202a-f). Device (312).

2. The apparatus of claim 1, wherein the opening devices (202a-f) are injection molding opening devices that perforate the web (102).

3. The apparatus of claim 1 or 2, wherein the air pulse device (318) is positioned to provide air pulses (320a-b) on opposite sides of the web (102).

4. 4. The apparatus of claim 1, wherein the air pulse device (318) comprises an air pulse pump (322) arranged to increase an air pulse pressure between successive air pulses, and air pulse valves (324a-b) configured to release the air pulse pressure to form the air pulses (320a-b).

5. The apparatus of claim 4, wherein the air pulse valves (324a-b) are radial valves or solenoid valves.

6. The apparatus of claim 4, wherein the air pulse pressure when the air pulse valves (324a-b) are open is between 1.5 and 5.0 bar.

7. The apparatus of any one of claims 1 to 6, wherein the sterilant (308) comprises hydrogen peroxide.

8. The apparatus of any one of claims 1 to 7, wherein the air pulse device (318) is configured to provide between 3 and 10 air pulses per second.

9. The apparatus according to any one of the preceding claims, wherein the positioning elements (204a-f) are magnetic marks integrated into the web (102).

10. a packaging material receiver (302) arranged to receive the web of packaging material (102); an opening device supplier (304) arranged to supply an opening device to the web (102); a sterilizing bath (306) arranged to supply a sterilizing agent (308) to said web (102); an apparatus (312) according to any one of claims 1 to 8, arranged to remove excess of the disinfectant (308) from aperture device regions (210a-f) of the web (102); a sterilization chamber (326) for sterilizing the web (102); a sterile chamber (328) for forming packages (112) from the web (102); A packaging system (300) comprising:

11. 11. The packaging system (300) of claim 10, wherein the opening device supplier (304) is an injection molding apparatus arranged to supply an injection molding opening device that perforates the web (102).

12. A method (400) for removing excess sanitizing agent (308) from a web (102) of carton-based packaging material, the web (102) comprising a plurality of successively arranged sections (200a-f) arranged to form a package (112), each section of the web (102) comprising an opening device (202a-f) attached thereto, at least a subset of the sections (200a-f) comprising positioning elements (204a-f); By excess germicide (308), it is meant that any amount of germicide present on the surface of the opening device (202a-f) that exceeds a predetermined germicide layer thickness; The method comprises: determining (402) the location of the positioning elements (204a-f) included in or on the web (102); estimating (404) a position of the opening device (202a-f) based on the position of the positioning element (204a-f); adjusting (406) an air pulse device (318) based on the position of the aperture device (202a-f); providing (408) air pulses (320ab) to the aperture device regions (210a-f) of the web (102) to remove excess of the germicide (308) from the aperture devices (202a-f); The method includes:

13. The method of claim 12, wherein the opening devices (202a-f) are injection molding opening devices that perforate the web (102).

14. 14. The method of claim 12 or 13, further comprising, prior to the step of determining (402) the positions of the positioning elements (204a-f), a step of supplying (410) the sterilizing agent (308) to the web (102) by passing the web (102) through a sterilizing bath (306).

15. increasing (412) the air pulse pressure by using an air pulse pressure pump (322); The method of any one of claims 12 to 14, wherein the step of providing the air pulse pressure (408) is performed by opening air pulse pressure valves (324a-b) to form the air pulses (320a-b).

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