Particle removal device and method for filling machines

Abstract

A particle removal device (18) for a filling machine (10) configured to form, fill, and seal individual packages (4) is provided, the particle removal device (18) comprising an air inlet pipe (181) and a controller (186) programmed to operate the particle removal device (18) to direct a jet of air at ready-to-fill packages (2) passing through the particle removal device (18).

Description

[Technical field]

[0001] The present invention relates to a filling machine, and in particular to a particle removal device for a filling machine configured to form, fill and seal individual packages. The present invention also relates to a method for removing particles from a package during its manufacture, i.e. during the formation and filling of the package. [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 group of packages that frequently appear are the 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] An open-ended packaging sleeve is received at the infeed station of the filling machine, after which the bottom end is formed and sealed. The semi-finished package is now ready to be filled. At a downstream station, the ready-to-fill package is pasteurized or sanitized, at least on the inside, to extend the shelf life of the product stored within the package. Different levels of pasteurization / sanitization can be used depending on the length of shelf life desired and whether the package will be distributed and stored in a refrigerated environment or at room temperature.

[0005] After sterilization, 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] It is important to produce packages with a minimum of unwanted particles, especially in the packaging of liquid foods. These particles are disadvantageous for many reasons. For example, large particles can negatively affect the quality of the enclosed product. Large particles can also negatively affect the performance of the filling machine, including the sealing operation. Furthermore, particles of any size can carry unwanted organisms, which poses hygiene issues. In addition to the above disadvantages, the presence of particles can also cause combustion when hydrogen peroxide is used as a sanitizing medium. Thus, there is a need for filling machines that improve the removal of particles from ready-to-fill packages. Summary of the Invention [Problem to be solved by the invention]

[0007] 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, it is an object to provide a particle removal device for a filling machine capable of removing particles from ready-to-fill packages. Because particles may be generated during the operation of producing ready-to-fill packages, it is advantageous to locate the particle removal device in the filling machine near where the particles are generated. [Means for solving the problem]

[0008] To achieve these objectives, a particle removal device is provided for use with a filling machine configured to form, fill and seal individual packages, the particle removal device including an air inlet pipe and a controller programmed to operate the particle removal device such that a jet of air is directed at ready-to-fill packages passing through the particle removal device.

[0009] The controller may be programmed to control operation of the particle removal device based on movement of ready-to-fill packages past the particle removal device.

[0010] The controller may be programmed to control operation of the particle remover for an entire indexing cycle during which two successive ready-to-fill packages pass through the particle remover.

[0011] In an embodiment, the jet of air is constant during operation of the particle removal device.

[0012] Operation of the particle removal device may be initiated when a leading sidewall of the ready-to-fill package is positioned in the same vertical plane as the orifice of the air inlet pipe.

[0013] The particle removal device may further comprise a hood, and the air intake pipe may be disposed inside the hood. The hood may comprise an exhaust unit. The orifice of the air intake pipe may be disposed vertically below a lower end of the hood.

[0014] The hood may be dimensioned to cover at least one ready-to-fill package.

[0015] According to a second aspect, there is provided a filling machine comprising a particle removal device according to the first aspect.

[0016] The filling machine may further comprise a cap applicator station, the particle removal device being positioned downstream of the cap applicator station.

[0017] The filling machine may further comprise a sanitizing station, the particle removal device being positioned upstream of the sanitizing station.

[0018] According to a third aspect, there is provided a method for a filling machine configured to form, fill and seal individual packages, the method comprising a first step of providing a particle removal device according to the first aspect, and activating the particle removal device such that a jet of air is directed into ready-to-fill packages passing through the particle removal device.

[0019] Further objects, features, aspects and advantages of the present invention will become apparent from the following detailed description and drawings.

[0020] 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]

[0021] [Figure 1] FIG. 1 is a schematic diagram of a filling machine according to one embodiment. [Diagram 2] FIG. 2 is an isometric view of a package produced by the filling machine shown in FIG. 1. [Diagram 3] 1 is a schematic diagram of a part of a filling machine including a particle removal device according to one embodiment. [Figure 4] FIG. 1 illustrates an isometric view of a particle removal device according to one embodiment. [Diagram 5] 1 is a diagram that generally illustrates the operation of a particle removal device. [Figure 6] 1 is a schematic diagram of a method according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] 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 into a sleeve and the lower end of each blank is sealed to form a semi-finished package which is closed at one lower end but still open at the upper end.

[0023] Upstream or downstream of the bottom sealing station 14, a cap applicator station 16 may be provided. The purpose of the cap applicator station 16 is to attach an opening device, such as a screw cap having an associated neck, to the sleeve-like blank 2. Typically, the neck and cap are provided as a pre-manufactured assembly and attachment to the sleeve-like blank is by ultrasonic sealing.

[0024] Located immediately downstream of the cap applicator station 16 is a particle remover 18. The particle remover 18 is configured to remove unwanted particles from the sleeve-like blanks prior to sterilization.

[0025] After passing through the particle removal device 18, the semi-finished packages are conveyed to a sterilization station 20 where the amount of live microorganisms is reduced. The level of sterilization may vary depending on the user's objectives. Sterilization of the packaging material may be accomplished, for example, by treatment with hydrogen peroxide, UV light, electron beam irradiation, etc.

[0026] Located downstream of the sterilization station 20 is a filling station 22, where ready-to-fill packages are filled with the desired contents. After filling, the packages may be conveyed to a pre-folding station 24, where the top of the open-ended 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 as the package enters a sealing station 28, located immediately behind the heating station 26.

[0027] Once sealed, the package 4 is ejected by a delivery station 30 .

[0028] It should be noted that the filling machine 10 need not be configured exactly as described with reference to FIG. 1, and that the filling machine 10 may be configured to produce other types of packages, such as plastic top packages, etc.

[0029] 2 shows an example of a package 4 produced by filling machine 10. Package 4 is a so-called gable top package and has a screw cap 6 attached to it. Screw cap 6 can be attached to package 4 using a screw cap applicator station 16, as described further below.

[0030] Specific components of the filling machine 10 are further illustrated in Figure 3. The sleeve-like blank 2 is conveyed through a cap applicator station 16 in a direction A, as indicated by the block arrow. The cap applicator station 16 may include an indexing rotating member 161 carrying an even number of cap application units 162 extending radially outward as spokes. In the illustrated example, there are eight cap application units 162, although other numbers are possible.

[0031] The indexing rotating member 161 does not rotate continuously but has four different effective positions, in each of which two adjacent cap application units 162 are positioned close to a respective blank 2, whereby these two blanks 2 are simultaneously provided with a respective cap 6. One of the four effective positions is shown in FIG.

[0032] The movement sequence of the indexing rotating member 161 also requires that the flow of blanks 2 be controlled in a similar manner. A blank 2 is positioned stationary relative to a valid cap application unit 162, after which the blank 2 is advanced until the next two blanks 2 are correctly positioned relative to the next valid cap application unit 162.

[0033] In FIG. 3, it can be seen that caps 6a and 6b are applied using cap application units 162a and 162b, respectively.

[0034] Located immediately downstream of the cap applicator station 16 is a particle remover 18. The particle remover 18 is configured to remove unwanted particles from the ready-to-fill packages leaving the cap applicator station 16.

[0035] Turning now to Figure 4, the particle remover 18 is shown in more detail. The particle remover 18 operates by supplying a flow of air, preferably clean air, to the ready-to-fill packages or sleeved blanks 2. To this end, the particle remover 18 comprises an air inlet pipe 181 which extends essentially vertically and has an orifice 182 at its end for admitting air into the package. The orifice 182 may be a single orifice or a series of orifices. Each orifice may have a circular, rectangular or any other suitable shape.

[0036] The air supply pipe 181, as well as its orifice 182, are disposed within a hood 183 that is dimensioned to cover at least one of the ready-to-fill packages when the particle removal device 18 is activated. The hood 183 is further in fluid communication with an exhaust unit 184 for allowing air to be drawn through the hood 183. The exhaust unit 184 may be constantly activated or may be controlled to exhaust air only when the particle removal device 18 is activated. The hood 183 may be oriented substantially vertically upwards, but may be bent, for example by forming an L-shape, to prevent exhausted particles from falling into the package directly below the hood 183.

[0037] The air intake pipe 181 is connected to a valve 185, which is controlled by a controller 186. The controller 186 is programmed to provide a control signal to the valve 185 so that the supply of air through the air intake pipe 181 is controlled accordingly. The air intake pipe 181 may extend vertically upwards or may be bent, for example by forming an L-shape, preferably a bent air intake pipe 181 may be used with a straight exhaust pipe from the hood 183, while a straight air intake pipe 181 may be used with a bent exhaust pipe from the hood 183.

[0038] 5, the operation of the particle remover 18 is shown diagrammatically. The different stages i) to ix) represent different positions in the stream of ready-to-fill packages or sleeve-like blanks 2 passing by the stationary particle remover 18, shown here only as an air inlet pipe 181.

[0039] At i), the package is stationary due to an ongoing capping process (not shown) upstream. At this point, the particle removal device 18 is inactive, i.e. no air flows out of the air intake pipe 181. However, the exhaust unit 184 may still be active.

[0040] In ii), the package moves in the direction of arrow A, away from the cap applicator station 16 and towards the sterilization station 20. When the package is aligned with the orifice 182 of the air supply pipe 181 such that the leading sidewall of the package is located in the same vertical plane as the orifice 182, the particle removal device 18 is operated by the controller 186 such that the valve 185 is opened to allow pressurized air to flow out of the orifice 182. Since the orifice 182 is located only a very small distance from the top edge of the package, such as in the range of 1-35 mm, an efficient jet is formed and propagates into the package without being adversely affected by the exhaust flow. The jet "sticks" to the inside of the sidewall of the package, which allows the jet to follow the inside of the package to the other side of the package, thereby efficiently removing particles from the bulk of the package as well as from the wall.

[0041] As the packages continue to advance, the supply air is directed essentially straight into the package, as shown at iii), until the trailing sidewall of the leading package is aligned with the orifice 182, as shown at iv). At this point the jet attaches to the trailing sidewall, effectively spreading the supplied air throughout the entire inside of the package. In v), the leading package is cleared, whereby the orifice 182 is aligned with the small space between two adjacent packages. The particle remover 18 is still operating, i.e. air is still being supplied from the orifice, but no particle removal actually occurs until the trailing package is aligned with the orifice 182, as shown at vi). Steps vi)-ix) are the same as steps ii)-v) in terms of particle removal operation, except that in ix) the package is stopped and remains stationary due to a capping operation that takes place upstream of the particle remover. At this point, the operation of the particle remover 18 is changed to a non-operating state by stopping the supply of air. During steps ii)-ix), the movement of the packages is continuous in direction A.

[0042] As described above, the technology concept is based on using the movement of the package / blank 2 against a pulsed air jet to dislodge particles from the ready-to-fill package or blank 2 and capture them by a controlled exhaust flow from the hood's exhaust unit 184.

[0043] The air supply pipe 181 is preferably a single inlet pipe that extends down a short distance from the top edge of the package to have an efficient jet that propagates far into the package or blank 2 without being adversely affected by the exhaust flow.

[0044] A single pulse of pressurized air covers both packages or blanks 2 of an indexing pair as they pass through the orifice 182. In this way, the movement of the packages or blanks 2 ensures wall deposition of the jet first on one side of the package wall and then on the other side of the package wall, thereby efficiently removing particles from the bulk of the package as well as from the wall. The placement, timing and length of the pulse are controlled to ensure wall deposition on both sides and both packages while still taking into account the air consumption. Preferably, the air pulse is started at the same time as the edge of the leading package goes under the inlet pipe and the air pulse is ended when the process is completed with the second / following package of the indexing pair, at ix) in FIG. 5. Alternatively, the particle remover 18 may be operated all the time so that air is always discharged from the air inlet pipe 181, even when the packages are stationary.

[0045] Particles exiting the package opening are efficiently captured by an upwardly positioned exhaust hood, preferably with a central exhaust pipe operating with a controlled steady flow. Because the air intake pipe 181 extends downwards and is therefore vertically below and separated from the exhaust point, the air jet is not adversely affected by the exhaust flow, which can still capture particles removed from the package. In this way, dust accumulation within the machine can be minimized. Control of the process may be based on the design of the hood with integral air intake pipe 181, the position of the air intake pipe 181 relative to the package, the indexing movement profile, the timing of the pulses controlled by valve 185, the pressurized air flow (preferably controlled by pressure) and the exhaust flow. A controlled flow of air during the entire pulse can be ensured by pressure control, preferably provided there is sufficient accumulation capacity before the valve 185.

[0046] The solution presented herein provides efficient particle removal from ready-to-fill packages or blanks 2 with a relatively low consumption of pressurized air. In particular, the presented solution is very efficient for removing not only larger particles but also smaller particles (down to 0.1 mm diameter). Since the particle removal device 18 is separate from the package sterilization station 20, optimal conditions for particle removal can be created without the limitations of the requirements of the package sterilization process and the requirement to maintain hygienic conditions in the hygiene zone.

[0047] The particle removal device 18 is a space-efficient solution since only one package location is required, but still processes both packages of an indexing pair. This space-efficient solution allows implementation downstream of the ultrasonic sealing of the cap, and therefore targets micron-sized particles that are generated during the ultrasonic cap sealing process. These small particles, which are still present in the bulk of the package, are preferably captured before they stick to the packaging material, for example due to electrostatic forces and the strength of van der Waals bonds between the particles and the walls of the package. The solution presented here allows for early processing of the package, washing away a significant portion of the small particles before they stick to the walls.

[0048] Another advantage of implementing the particle removal device 18 before the package sterilization station 20 is that the particle removal function is independent of the processes of package sterilization and maintaining sanitary chamber conditions, respectively, thereby providing efficient particle removal without compromising these important functions. This allows the particle removal device 18 to be operated after or at the end of the sterilization process without increasing the risk of package recontamination, thereby lowering the risk of package recontamination after sterilization. It also allows optimization of the package sterilization process without compromising the particle removal function.

[0049] 6, a method 100 is shown generally. The method 100 is carried out in a filling machine configured to form, fill and seal individual packages. The method 100 includes the step 102 of providing a particle removal device 18 in accordance with the above description, and the step 104 of operating the particle removal device such that a jet of air is directed into ready-to-fill packages passing through the particle removal device.

[0050] From the above description, it can be seen that while various embodiments of the invention have been described and illustrated, the 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. A particle removal device (18) for a filling machine (10) configured for forming, filling and sealing individual packages (4), the particle removal device (18) comprising an air intake pipe (181), a controller (186) programmed to control the particle removal device (18) so that a jet of air is directed at a ready-to-fill package (2) passing through the particle removal device (18); the controller (186) is programmed to control operation of the particle removal device (18) based on movement of a pair of ready-to-fill packages (2); operation of the particle removal device (18) begins when a sidewall of a leading package of the pair of ready-to-fill packages is located in the same vertical plane as an orifice (182) of the air inlet pipe (181) and ends after a trailing package of the pair of ready-to-fill packages has passed through the air inlet pipe (181); Particle removal device (18).

2. 2. The particle removal apparatus of claim 1, further comprising a hood (183), the air supply pipe (181) being disposed inside the hood (183).

3. The particle removal apparatus of claim 2 , wherein the hood (183) comprises an exhaust unit (184).

4. 4. A particle removal device according to claim 2 or 3, wherein the orifice (182) of the air supply pipe (181) is located vertically below the lower end of the hood (183).

5. A particle removal device according to any one of claims 2 to 4, wherein the hood (183) is dimensioned to cover at least one ready-to-fill package.

6. A filling machine (10) comprising a particle removal device according to any one of the preceding claims.

7. 7. The filling machine of claim 6, further comprising a cap applicator station (16), said particle removal device (19) being disposed downstream of said cap applicator station (16).

8. 8. The filling machine according to claim 6 or 7, further comprising a sterilization station (20), the particle removal device (18) being arranged upstream of the sterilization station (20).

9. A method for a filling machine configured to form, fill and seal individual packages (4), comprising the steps of: Providing a particle removal device (18) according to any one of claims 1 to 5; and operating the particle removal device (18) such that a jet of air is directed into a ready-to-fill package (2) passing through the particle removal device (18). The method includes:

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