Production line and production method

Abstract

To reduce a frequency of product liquid discarded by water replacement of a product liquid sterilizer.SOLUTION: A manufacturing line includes: a sterilizer that sterilizes product liquid; a sterilized tank that receives and stores the product liquid from the sterilizer; a sterilization flow rate adjustment part configured to be able to adjust a sterilization flow rate corresponding to a flow rate of the product liquid sent to the sterilized tank; a filling machine that fills a container with the product liquid supplied from the sterilized tank; an accumulation conveyance device that is configured to be able to store the container filled with the product liquid and that conveys the container toward, a downstream direction; and a control device configured to be able to control at least a part of the manufacturing line. When a loading rate of the container in the accumulation conveyance device increases and reaches a predetermined reference value, the control device causes the sterilization flow rate adjustment part to reduce the sterilization flow rate.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present disclosure relates to a production line including a sterilization device that sterilizes a product liquid, a filling machine, and an aseptic tank disposed between the sterilization device and the filling machine, and a production method using the production line. [Background technology]

[0002] A line for producing beverage products in which a product liquid such as a beverage is filled into containers includes a product liquid sterilization device that sterilizes the product liquid, an aseptic tank that stores the sterilized product liquid, a filling machine that fills the product liquid supplied from the aseptic tank into containers, and an accumulation conveyor that is configured to accumulate filled containers and transports the containers to downstream processes where inspection, boxing, etc. are performed.

[0003] As shown in Patent Document 1, for example, the product liquid sterilization and storage line upstream of the filling machine includes a cushion tank for storing unsterilized product liquid, a sterilizer that sterilizes the product liquid by heating it, and an aseptic tank that stores the product liquid sent from the sterilizer and supplies it to the filling machine. The sterilizer includes a heat exchanger that exchanges heat between a heating medium and the product liquid, an insulated tube through which the heated product liquid flows while maintaining a constant temperature for a predetermined period of time, and a cooler that cools the product liquid. To ensure the specified sterilization performance, the flow rate and temperature of the product liquid flowing through the sterilizer are controlled.

[0004] In order to prevent the filling machine from stopping operation, the sterilization capacity of the product liquid sterilizer is set slightly higher than the filling capacity of the filling machine. In other words, the flow rate of the product liquid flowing from the sterilizer to the aseptic tank is slightly higher than the flow rate of the product liquid supplied from the aseptic tank to the filling machine, so the liquid level in the aseptic tank gradually rises.

[0005] In Patent Document 1, when the product liquid in the sterile tank exceeds a level corresponding to half the capacity, the amount of liquid sent by the variable flow pump that sends the product liquid from the cushion tank to the heating heat exchanger is reduced in accordance with the product liquid level in the sterile tank measured by a level gauge in order to prevent further rise in the liquid level. Thereafter, when the liquid level in the sterile tank becomes full, the three-way valve in the liquid sending pipe that sends the sterilized product liquid to the sterile tank is switched, so that the product liquid is returned to the cushion tank without being received by the sterile tank, and a circulation path including the product liquid path in the sterilizer is formed to circulate the water that has been replaced with the product liquid.

[0006] The replacement of the product liquid with water in the sterilizer is carried out to prevent the product liquid from deteriorating due to retention in the heating heat exchanger or repeated heating, and to ensure a constant amount of liquid is sent to the sterilizer in order to stabilize the control of the sterilizer. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 9-010286 Summary of the Invention [Problem to be solved by the invention]

[0008] Even if the flow rate of the product liquid sent to the sterile tank by the sterilizer is reduced according to the liquid level in the sterile tank as in Patent Document 1, if the filling machine stops, the liquid level in the sterile tank will rise rapidly compared to normal operation and approach full capacity. This forces the sterile tank to stop receiving the product liquid and the sterilizer to replace the product liquid with water. During water replacement, the product liquid in the sterilizer's path is discarded. In other words, whenever the liquid level in the sterile tank exceeds a predetermined level due to the filling machine being stopped, the product liquid is discarded as the sterilizer replaces the water. Therefore, an object of the present disclosure is to reduce the frequency with which product liquid is discarded due to water replacement in a product liquid sterilization device. [Means for solving the problem]

[0009] The production line according to the present disclosure comprises a sterilization device that sterilizes the product liquid, a sterile tank that receives and stores the product liquid from the sterilization device, a sterilization flow rate adjustment unit that is configured to adjust the sterilization flow rate corresponding to the flow rate of the product liquid sent to the sterile tank, a filling machine that fills containers with the product liquid supplied from the sterile tank, an accumulation and conveying device that is configured to accumulate containers filled with the product liquid and conveys the containers downstream, and a control device that is configured to be able to control at least a portion of the production line. When the container loading rate in the storage and transport device increases and reaches a predetermined reference value, the control device reduces the sterilization flow rate using the sterilization flow rate adjustment unit.

[0010] Another production line according to the present disclosure includes a sterilization device that sterilizes the product liquid, a sterile tank that receives and stores the product liquid from the sterilization device, a sterilization flow rate adjustment unit that is configured to adjust the sterilization flow rate corresponding to the flow rate of the product liquid sent to the sterile tank, a filling machine that fills containers with the product liquid supplied from the sterile tank, and a control device that is configured to control at least a portion of the production line. The control device reduces the sterilization flow rate by the sterilization flow rate adjusting section when a predetermined reference time has elapsed since the abnormal stop of the processing device that processes the containers downstream of the filling machine.

[0011] The manufacturing method according to the present disclosure is a manufacturing method using a manufacturing line, which at least includes a sterilization device that sterilizes the product liquid, a sterile tank that receives and stores the product liquid from the sterilization device, a sterilization flow rate adjustment unit configured to adjust the sterilization flow rate corresponding to the flow rate of the product liquid sent to the sterile tank, a filling machine that fills containers with the product liquid supplied from the sterile tank, an accumulation and conveying device configured to accumulate containers filled with the product liquid and convey the containers downstream, and a control device configured to be able to control at least a portion of the manufacturing line. In this manufacturing method, by carrying out either (A) or (B), the rise in the liquid level in the aseptic tank is suppressed. (A) When a predetermined reference time has elapsed since a processing device that processes containers downstream of the filling machine stopped due to an abnormality, the sterilization flow rate adjustment unit reduces the sterilization flow rate. (B) If the production line is configured to be able to accumulate containers filled with product liquid and is equipped with an accumulation and conveying device that conveys the containers downstream, when the container loading rate in the accumulation and conveying device increases and reaches a predetermined standard value, the sterilization flow rate is reduced by the sterilization flow rate adjustment unit. [Effects of the Invention]

[0012] The manufacturing line and manufacturing method disclosed herein are based on the ability to predict the stoppage of a filling machine by detecting an increase in loading rate due to the inability of a storage and conveying device that stores containers received from the filling machine to dispense them downstream, or by detecting an abnormal stoppage in a processing device downstream of the filling machine. According to the present disclosure, the sterilization flow rate can be limited by the flow rate adjuster of the sterilization device from a point in time that is sufficiently earlier than when the sterilization flow rate is reduced based on the liquid level after the filling machine has stopped, based on the reference load rate reaching a reference value or the elapsed reference time since the downstream processing device abnormally stopped. According to the present disclosure, even if the sterilization flow rate cannot be significantly reduced compared to steady-state operation due to the stability of temperature and flow rate control in the sterilization device, it is possible to prevent the liquid level in the aseptic tank from reaching its upper limit too soon after the filling machine has stopped, causing the sterilization device to perform water replacement. This reduces the frequency of product liquid disposal due to water replacement, improving yield. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a schematic diagram illustrating devices constituting a manufacturing line according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a diagram showing an example of a schematic configuration of the sterilization device shown in FIG. [Figure 3] FIG. 2 is a schematic plan view of the storage and transport device shown in FIG. [Figure 4]10 is a graph showing an example of the change over time in the liquid level of the sterile tank and the loading rate of the storage and transport device in this embodiment. When the loading rate increases and reaches a reference value, the flow rate of the liquid sent from the sterilizer to the sterile tank is reduced. [Figure 5] 10 is a graph showing an example of the change over time in the liquid level of the sterile tank and the loading rate of the storage and transport device for a comparative example. The liquid level rises and reaches a reference value, which triggers a reduction in the flow rate of the liquid sent from the sterilizer to the sterile tank. DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, embodiments will be described with reference to the accompanying drawings. [Production line overview] 1 corresponds to, for example, a part of a line that produces packaged beverage products. The production line 1 includes a sterilization device 10, an aseptic tank 20, a filling machine 30, an accumulating and conveying device 40, a processing device 50, and a control device 60 that is configured to be able to control at least a part of the production line 1. From upstream u to downstream d of the production line 1, the sterilization device 10, the aseptic tank 20, the filling machine 30, the accumulating and conveying device 40, and the processing device 50 are arranged in this order.

[0015] The filling machine 30 fills and seals containers (not shown), such as plastic bottles, cans, and jars, with the product liquid that has been sterilized (in a sterile state) by the sterilizer 10. The filling machine 30 preferably corresponds to an aseptic filling machine that performs filling and sealing processes in an atmosphere maintained in a sterile state inside a housing (not shown). The containers filled with the product liquid are transported and stored by the accumulation and conveyance device 40, and are supplied from the accumulation and conveyance device 40 to the processing device 50.

[0016] The processing device 50 corresponds to a single device or a group of devices that perform some kind of processing on containers, such as an inspection device that inspects containers, a labeler that attaches labels to resin bottles, or a caser that packs containers into boxes, and is located downstream of the storage and conveying device 40. The processing device 50 may include a combiner that reduces the number of rows of containers while conveying the containers.

[0017] The control device 60 controls the operating state of the devices by driving valves, motors, etc. of the devices that make up the production line 1 and by issuing commands based on values ​​detected by sensors. The control device 60 corresponds to a computer device equipped with a memory, a calculation unit, and a storage unit, and performs various controls based on computer programs that are read from the storage unit and executed.

[0018] In order to operate the filling machine 30 continuously and stably, during steady operation, it is preferable that the sterilization capacity C1 set in the upstream sterilization device 10 be set slightly higher than the filling capacity C3 set in the filling machine 30. For the same reason, it is also preferable that the processing capacity C5 set in the processing device 50 be set higher than the filling capacity C3 during steady operation. If the filling capacity C3 is 100%, the sterilization capacity C1 can be set to, for example, 101 to 110%, and the treatment capacity C5 can be set to, for example, 110 to 130%. The "capacity" can be converted into the number of containers that the sterilization device 10, the filling machine 30, and the processing device 50 process per unit time (for example, BPM; Bottles Per Minute).

[0019] [Sterilizer and aseptic tank] The sterilizer 10 sterilizes a liquid product prepared by a process (not shown) by heating. As shown in Fig. 2, the sterilizer 10 includes a cushion tank 11, a pump device 12, a heater 13, a heat-retaining tube 14, a three-way valve 101, a replacement tank 102, a discharge valve 103, and a filter (not shown). The sterilizer 10 may include a cooler as needed.

[0020] The heater 13 heats the product liquid by exchanging heat between the product liquid flowing through the flow path 131 and a heating medium (e.g., hot water) supplied to the flow path 132 by the heat source circuit 130. The heat-retaining tube 14 is covered with a heat insulating material, and therefore maintains the product liquid flowing from the heater 13 at a certain temperature or higher.

[0021] The unsterilized product liquid supplied from the blending process to the cushion tank 11 is pressure-fed by the pump device 12 through the flow path 131 of the heater 13 and the heat-retaining tube 14, and is supplied to the aseptic tank 20 via the piping 15, the first three-way valve 101, and the piping 16. The inside of the aseptic tank 20 is pressurized as necessary. The product liquid is supplied from the aseptic tank 20 to the filling machine 30 by the pressure of the product liquid stored in the aseptic tank 20 or by a pump (not shown).

[0022] The product liquid is sterilized to a sterile state by being maintained at a temperature equal to or higher than a certain level for a predetermined period of time while flowing through the flow path 131 and the heat-retaining tube 14. In order to ensure a predetermined sterilization degree, the control device 60 controls the flow rate and temperature of the product liquid flowing through the sterilization device 10 to a predetermined set flow rate and a predetermined set temperature, respectively.

[0023] The pump device 12 is configured to be able to adjust the flow rate of the product liquid. Although the components of the pump device 12 are not shown, the pump device 12 may include, for example, a fixed displacement pump, a servo motor configured to be able to adjust the operating speed of the fixed displacement pump, and a valve that corresponds one of the inlet ports P1 and P2 to the outlet port P3. The pump device 12 may include a variable displacement pump, or may include a fixed displacement pump and a flow rate adjustment valve.

[0024] The pump device 12 functions as a sterilization flow rate adjusting section that can adjust the sterilization flow rate F, which corresponds to the flow rate of the product liquid sent toward the aseptic tank 20. The pump device 12 adjusts the sterilization flow rate F by controlling the drive of the servo motor and controlling the opening of the flow rate adjustment valve according to a control signal issued from the control device 60.

[0025] During steady-state operation, the sterilization capacity C1 exceeds the filling capacity C3, so the liquid level in the aseptic tank 20 gradually rises. The sterilization device 10 continues to send the liquid to the aseptic tank 20 unless the liquid level L of the product liquid in the aseptic tank 20 reaches the upper limit liquid level LV2.

[0026] [Storage and transport device] The accumulation and transport device 40 is configured to be able to accumulate containers discharged from the filling machine 30, and includes a plurality of conveyor devices 401-408 that transport the containers downstream, as shown in Fig. 3, for example. The transport area 41 of each of the conveyor devices 401-408 is provided with a width that allows multiple containers to be arranged in a direction perpendicular to the transport direction D1. In other words, the containers can be loaded in the transport area 41 so that they are lined up in multiple rows in the transport direction D1.

[0027] The control device 60 calculates the loading rate r of each of the conveyor devices 401-408 based on the overall loading rate R of the storage and transport device 40. Then, based on the loading rate r set for each of the conveyor devices 401-408, the control device 60 controls the driving speed of the motor corresponding to each of the conveyor devices 401-408. Depending on the driving speed of each of the conveyor devices 401 to 408, the containers are arranged at intervals in the conveying direction D1 or closely in the conveying direction D1.

[0028] For example, when a group of containers is placed in the conveying area 41 of the accumulation and conveying device 40 and the operation of the filling machine 30 and the manufacturing line 1 is started through the processes upstream u and downstream d of the filling machine 30, the accumulation and conveying device 40 can receive containers from the filling machine 30 upstream u via the discharge conveyor 31 and supply the containers to the processing device 50 downstream d. While the containers are being transported by the discharge conveyor 31, processes such as cleaning the container lids, removing water droplets from the containers, and printing on the containers with a laser may be performed as necessary.

[0029] The accumulation and conveyance device 40 receives containers from the filling machine 30 and stores them in the conveyance area 41, even while the line downstream d from the accumulation and conveyance device 40 is stopped due to the stoppage of at least some of the processing equipment 50. Furthermore, even while the filling machine 30 is stopped, containers are supplied from the accumulation and conveyance device 40 to the line downstream d. When the accumulation and conveyance device 40 stores containers, the containers are basically stored from the conveyor device 401 downstream d toward the upstream u.

[0030] If the equipment upstream u or downstream d of the accumulation and conveyance device 40 is temporarily stopped, or if the filling machine 30 and the equipment upstream u thereof are stopped for cleaning, sterilization, etc., the difference in capacity between the upstream u and downstream d of the accumulation and conveyance device 40 changes, and so the conveyance capacity C4 required of the accumulation and conveyance device 40 also changes. As the conveyance capacity C4 set for the accumulation and conveyance device 40 changes, the overall loading rate R changes, and the individual loading rates r also change, so the number and arrangement of containers on the conveyance area 41 changes.

[0031] The loading rate r of each of the conveyor devices 401 to 408 refers to the ratio of the area occupied by the containers to the area (effective area) in the transport area 41 in which the containers can be placed. The overall loading ratio R of the accumulation and transport device 40 refers to the ratio of the area occupied by containers to the effective area of ​​the entire transport region 41 of the conveyor devices 401-408. In this embodiment, the overall loading rate R is calculated solely by the control device 60 using the conveying capacity C4 of the storage and conveying device 40 and the number of rows of containers determined from the width of the conveying area 41 and the dimensions of the containers. However, this is not limiting, and the overall loading rate R may also be obtained by detecting the position and speed of the containers conveyed by the storage and conveying device 40 using a photoelectric sensor, a camera, or the like.

[0032] [Control of liquid level rise in sterile tank] When the liquid level L in the sterile tank 20 reaches the reference liquid level LV1, the control device 60 preferably reduces the sterilization flow rate F to lower the rate of increase of the liquid level L over time, thereby extending the time required for the liquid level L to reach the upper limit liquid level LV2. Therefore, based on the liquid level L measured by the liquid level meter 201 provided in the sterile tank 20, the control device 60 reduces the sterilization flow rate F when the liquid level L reaches a reference liquid level LV1.

[0033] To ensure the sterilization degree of the product liquid, it is necessary to suppress fluctuations in the heat load in heater 13 and maintain stable temperature and flow rate control. Therefore, it is preferable to gradually or stepwise reduce the sterilization flow rate F by providing to pump device 12 a control signal that changes the control amount gradually or stepwise over the range in which the sterilization flow rate F is reduced.

[0034] Even if the rate of rise of the liquid level L is slowed down by reducing the sterilization flow rate F, the liquid level L will eventually reach the upper limit liquid level LV2. When the liquid level L reaches the upper limit liquid level LV2, the control device 60 performs a process that involves discarding the product liquid present in the sterilization device 10.

[0035] For example, the control device 60 operates the first three-way valve 101 to receive the product liquid from the pipe 15 into the replacement tank 102, and opens the discharge valve 103 to discard the product liquid. Thereafter, the product liquid in the path of the sterilization device 10 is replaced with water (sterile water). To perform this replacement, for example, discharge valve 103 is closed to supply water to replacement tank 102 from a water supply source (not shown), and the inlet port of pump device 12 is switched to P2. In this state, pump device 12 circulates water through circulation path C made up of replacement tank 102, heater 13, heat retention tube 14, piping 15, and piping 17. While circulating water through circulation path C, it is waited for the liquid level L in sterile tank 20 to drop as the product liquid flows out from sterile tank 20 to filling machine 30.

[0036] The replacement of water with product liquid is performed, for example, by circulating the product liquid through circulation path C. After the water in heater 13, heat retention tube 14, and piping 15 has been replaced with product liquid, the three-way valve 101 is operated and the inlet port of pump device 12 is switched to P1, thereby starting the transfer of product liquid from cushion tank 11 to sterile tank 20. After liquid level L reaches upper limit liquid level LV2, the liquid temperature and flow rate are continuously controlled while the replacement with water and the replacement with product liquid are being performed, so that the control of the liquid temperature and flow rate remains stable even after the start of the transfer of liquid to sterile tank 20. The sterilization device 10 is equipped with a water replacement mode M2 ​​that performs a series of processes when the liquid level L reaches the upper limit liquid level LV2, including replacing the product liquid with water and restoring the product liquid to a state where it can be sent to the aseptic tank 20.

[0037] However, even if the liquid transfer from the sterile tank 20 to the filling machine 30 stops when the filling machine 30 stops, the liquid transfer from the sterilizer 10 to the sterile tank 20 does not stop, so the liquid level L in the sterile tank 20 rises rapidly. As a result, even if the sterilization flow rate F is reduced once the liquid level L reaches the reference liquid level LV1 after the filling machine 30 stops, the liquid level L will quickly reach the upper limit liquid level LV2.

[0038] The stopping of the filling machine 30 is caused, for example, by a buildup of containers on the conveying area 41 of the accumulation and conveying device 40 due to the inability to dispense containers from the accumulation and conveying device 40 to the downstream d due to factors such as a stoppage of the processing device 50. As the containers accumulate, the loading rate R increases, and when the loading rate R reaches the upper limit threshold for the accumulation and conveying device 40 to stably accept containers from the filling machine 30, the control device 60 stops the filling machine 30. Here, the loading ratio R increases only when the line downstream d from the accumulation and transfer device 40 stops and the containers cannot be dispensed from the accumulation and transfer device 40 to the downstream d. Furthermore, the loading rate R functions as a trigger for stopping / restarting the filling machine 30 by setting an upper limit threshold and a lower limit threshold.

[0039] From the above, if the loading rate R increases and reaches a reference value RV1 that is lower than the upper threshold, it can be predicted that the filling machine 30 will soon stop and the liquid level L will rise rapidly. Therefore, regardless of the liquid level L, the control device 60 of this embodiment reduces the sterilization flow rate F based on the fact that the loading rate R has increased and reached the reference value RV1.

[0040] The reference value RV1 can be set to an appropriate value depending on the respective capacities of the storage and transport device 40 and the aseptic tank 20, the respective capabilities of the sterilizer 10, the filling machine 30, and the processing device 50, and the like.

[0041] [Specific control examples] An example of control relating to the rise in the liquid level in the sterile tank 20 will be described with reference to FIG. 4 and FIG. 5 showing a comparative example. In Figures 4 and 5, the liquid level L is shown by a solid line, and the loading rate R is shown by a dashed line. Figures 4 and 5 show data obtained with the same device configuration, except that the trigger for reducing the sterilization flow rate F is different. The capacity of the sterile tank 20 and the upper limit liquid level LV2 are the same.

[0042] FIG. 4 shows the operation of this embodiment through the changes in the liquid level L and the loading rate R over time. In the control example shown in FIG. 4, the production line 1 is initially in steady operation from upstream u to downstream d of the storage and transport device 40 (step S00). During steady-state operation, if the processing device 50 stops due to, for example, a container getting caught in the processing mechanism, the line d downstream of the accumulation and conveyance device 40 stops (step S01). As a result, the loading rate R increases and reaches a reference value RV1, and at that point, a process to reduce the sterilization flow rate F is initiated prior to stopping the filling machine 30 (step S02). When the filling machine 30 stops (step S03), the liquid level L rises sharply (state L2). Thereafter, when the line d downstream of the accumulation and conveyance device 40 restarts (step S04), the filling machine 30 restarts (step S05).

[0043] Each of steps S00 to S05 will be explained in detail below. Steady-state operation step S00: During steady operation, the capacity of the downstream d is greater than the capacity C3 of the filling machine 30, so the loading rate R decreases (state R0). Furthermore, during steady operation, the sterilization capacity C1 is slightly greater than the filling capacity C3, so the sterilization flow rate F sent to the sterile tank 20 is greater than the filling flow rate FF sent from the sterile tank 20 to the filling machine 30. Therefore, the liquid level L in the sterile tank 20 gradually rises (state L0). At this time, the sterilization flow rate F is controlled to a constant value by the pump device 12. Unlike the control example shown in Fig. 4, if the liquid level L gradually rises during steady operation and reaches the reference liquid level LV1, the control device 60 reduces the sterilization flow rate F by the pump device 12 regardless of the loading rate R. This reduces the rate at which the liquid level L rises toward the upper limit liquid level LV2.

[0044] Downstream line stop step S01: When the line downstream d from the accumulation and conveying device 40 stops (step S01), containers supplied from the filling machine 30 are accumulated in the accumulation and conveying device 40 without any containers being dispensed from the accumulation and conveying device 40 downstream d, and the loading rate R increases rapidly (state R1).

[0045] Sterilization flow rate reduction step S02: The loading rate R reaches the reference value RV1 at time t1, when time T1 has elapsed since time t0 when the line d downstream of the accumulation and conveyance device 40 stopped. Therefore, the control device 60 switches the sterilization device 10 to a flow rate reduction mode M1 in which the sterilization flow rate F is reduced, and causes the pump device 12 to reduce the sterilization flow rate F to a predetermined flow rate (step S02). In this control example, the reduction in the sterilization flow rate F reverses the difference between the sterilization capacity C1 and the filling capacity C3, causing the liquid level L to drop (state L1).

[0046] Stop filling machine step S03: After that, the loading rate R reaches the upper limit threshold RT1 for stably receiving containers into the accumulation and conveyance device 40. Therefore, the control device 60 starts processing to stop the operation of the filling machine 30 (step S03). This processing, for example, closes a stopper (not shown) provided on the container supply path of the filling machine 30 and closes the valve 18 between the sterile tank 20 and the filling machine 30 to stop the liquid transfer from the sterile tank 20 to the filling machine 30. The filling machine 30 then fills and seals the unfilled containers that have already been supplied with the product liquid, and while slowing down its operating speed toward stopping, discharges the containers toward the accumulation and conveyance device 40. The loading rate R increases until the discharge of containers from the filling machine 30 is completed. Then, when no containers are entering or leaving the accumulation and conveyance device 40, the loading rate R becomes constant (state R2).

[0047] Even if the liquid transfer from the sterile tank 20 to the filling machine 30 is stopped when the filling machine 30 is stopped (step S03), the liquid transfer from the sterilizer 10 to the sterile tank 20 continues in order to stabilize the temperature and flow rate control of the sterilizer 10. Therefore, when the filling machine 30 is stopped, the sterilization capacity C1 and filling capacity C3 are reversed again, and the liquid level L rises rapidly compared to during steady operation (state L2).

[0048] Downstream line restart step S04: Thereafter, when the line downstream d from the accumulation and transfer device 40 is restarted (step S04), containers are supplied from the accumulation and transfer device 40 to the downstream d, and the loading ratio R decreases (state R3).

[0049] Filling machine restart step S05: At time t3 when the loading rate R has decreased to a lower threshold RT2 that is sufficiently lower than the upper threshold RT1, the valve 18 is opened to start transferring the liquid from the sterile tank 20 to the filling machine 30, the filling machine 30 is restarted, and the sterilization device 10 is transitioned from the reduced flow rate mode M1 to steady operation (step S05). Upon completion of the reduced flow rate mode M1, the control device 60 increases the sterilization flow rate F by the pump device 12 to the flow rate during steady operation.

[0050] In other words, the sterilization flow rate F is limited to the flow rate during steady-state operation from t1, when the loading rate R reaches the reference value RV1, through the decrease in the loading rate R due to the restart of the downstream line (state R3), to t3, when the loading rate R reaches the lower threshold value RT2. In addition, it is preferable that the control device 60 gradually or stepwise increases the sterilization flow rate F by providing a control signal to the pump device 12 that changes the control amount gradually or stepwise over the range in which the sterilization flow rate F is increased, just as it does when decreasing the sterilization flow rate F.

[0051] 4, after the line d downstream of the storage and transport device 40 is restarted (step S04), the liquid level L has not reached the upper limit liquid level LV2 before the filling machine 30 is restarted (step S05) and the liquid is resumed from the sterile tank 20 to the filling machine 30. Therefore, the sterilization device 10 transitions to steady operation without transitioning from the flow rate reduction mode M1 to the water replacement mode M2.

[0052] [Control of Comparative Example] Next, the control of the comparative example shown in Fig. 5 will be described. In the comparative example, after the filling machine 30 has stopped, the sterilization flow rate F is reduced at time t2 when the liquid level L reaches the reference liquid level LV1. Therefore, the manufacturing process according to the comparative example proceeds in the order of a normal operation step s00, a downstream line stop step s01, a filling machine stop step s02, a sterilization flow rate reduction step s03, a downstream line restart step s04, and a filling machine restart step s06.

[0053] When the liquid level L reaches the reference liquid level LV1 due to the rise in the liquid level L caused by the stopping of the filling machine 30 (step s02), the sterilization device 10 shifts to a flow rate reduction mode M1 in which the sterilization flow rate F is reduced (step s03). The range in which the sterilization flow rate F is reduced in the comparative example may be the same as or different from the range in which the sterilization flow rate F is reduced in the control example shown in FIG.

[0054] Although the sterilization flow rate F decreases, the liquid level L rises (state L2) because the liquid supply from the sterile tank 20 to the filling machine 30 has stopped. Therefore, depending on the time T3 required for the line d downstream of the accumulation and transfer device 40 to restart, or the time T4 required for the line d downstream of the accumulation and transfer device 40 to restart, the liquid level L in the sterile tank 20 may reach the upper limit liquid level LV2, and the sterilization apparatus 10 transitions to water replacement mode M2 ​​(water replacement mode transition step s05). To transition to water replacement mode M2, the three-way valve 101 is switched from the piping 16 side to the piping 17 side to stop the supply of product liquid to the sterile tank 20.

[0055] In water replacement mode M2, the product liquid flows out from the sterile tank 20 to the filling machine 30 while the inflow of the product liquid into the sterile tank 20 is stopped, so the liquid level L decreases (state L3). After completing water replacement mode M2, the sterilization device 10 transitions to steady operation.

[0056] [Effects of this embodiment] The production line 1 and the production method using the production line 1 of this embodiment monitor the loading rate R based on the fact that the operating status of downstream processing equipment 50 is summarized as a single piece of information, the loading rate R. By reducing the sterilization flow rate F when the loading rate R increases and reaches a reference value RV1, the flow rate reduction mode M1 can be initiated much earlier than when the sterilization flow rate F is reduced based on the liquid level L after the filling machine 30 has stopped (comparative example). Therefore, even if the sterilization flow rate F cannot be significantly reduced compared to during steady operation from the perspective of stability of temperature and flow rate control, it is possible to prevent the liquid level L from reaching the upper limit liquid level LV2 too early after the filling machine 30 has stopped, causing the sterilization device 10 to transition to water replacement mode M2. This reduces the frequency of water replacement mode M2, thereby reducing the amount of product liquid wasted.

[0057] Furthermore, according to this embodiment, the loading rate R reaches the reference value RV1 before step S03, which stops the filling machine 30. In other words, the reference value RV1 is set to the loading rate R while the filling machine 30 is in operation. Therefore, prior to stopping the filling machine 30, the flow rate reduction mode M1 can be started from the time t1 when the loading rate R reaches the reference value RV1, which is highly effective in suppressing the rise in the liquid level L.

[0058] However, the reference value RV1 is not limited to this, and an upper limit threshold RT1 corresponding to the stop of the filling machine 30 can be used as the reference value. Even when the flow rate reduction mode M1 is started when the loading rate R reaches the upper limit threshold RT1 as a reference value (t1-1), the flow rate reduction mode M1 can be started at a sufficiently earlier point in time compared to when the flow rate reduction mode M1 is started at t2 when the liquid level L reaches the reference liquid level LV1, as in the comparative example. By suppressing the rise in the liquid level L from the start to the end of the flow rate reduction mode M1, it is possible to avoid transitioning to the water replacement mode M2 ​​as much as possible and reduce the amount of product liquid wasted.

[0059] According to this embodiment, it is possible to deal with the rise in the liquid level in the sterile tank 20 when the filling machine 30 is stopped simply by changing the trigger for performing the process of reducing the sterilization flow rate F, that is, by changing the trigger from when the liquid level L reaches the reference liquid level LV1 to when the loading rate R reaches the reference value RV1. The trigger can be easily changed by modifying the computer program.

[0060] [Modification] As described above, during steady-state operation, the processing capacity C5 downstream of the accumulation and conveyance device 40 is set higher than the filling capacity C3 upstream of the accumulation and conveyance device 40. A change in at least one of the filling capacity C3 and the processing capacity C5 changes the difference between the filling capacity C3 and the processing capacity C5. The slope of the loading ratio R when the line d downstream of the accumulation and conveyance device 40 stops (see state R1 in FIG. 4) changes depending on the capacity difference between C3 and C5. Therefore, it is preferable that the control device 60 adjusts the reference value RV1 depending on the capacity difference between the upstream of the accumulation and conveyance device 40 and the downstream of the accumulation and conveyance device 40. For example, consider the following case. Assume that the capacity of processing device 50 can be variably set, for example, to high, medium, or low. When processing device 50 is set to high, the difference between filling capacity C3 and processing capacity C5 is relatively large. In this case, during steady-state operation from sterilizer C1 to processing device 50, when processing device 50 stops, containers accumulate in storage / transport device 40 at a high rate. Therefore, the slope of loading rate R in the graph of FIG. 4 is steep (state R1), and the time until filling machine 30 stops is short. Even so, when the capacity difference between filling capacity C3 and processing capacity C5 is relatively large, control device 60 adjusts reference value RV1 to be lower than when the capacity difference is relatively small. This triggers the process of reducing the flow rate (F) of liquid sent to sterile tank 20 to start earlier, triggered by loading rate R reaching reference value RV1. Since the flow rate of the liquid sent to the sterile tank 20 is gradually reduced by the sterilization device 10, starting the flow rate reduction process early is advantageous in suppressing an increase in the liquid level L in the sterile tank 20.

[0061] As described above, when the line d downstream of the accumulation and conveyance device 40 stops, the loading rate R increases. Therefore, by knowing the stopped state of the processing device 50 on the downstream line, it is possible to predict the stop of the filling machine 30 and limit the sterilization flow rate F to a predetermined flow rate in advance in preparation for a sudden rise in the liquid level L that accompanies the stop of the filling machine 30. This case can also be explained with reference to FIG. 4. That is, instead of the loading rate R, the sterilization flow rate F is reduced when a predetermined reference time (for example, T1) has elapsed since the time t0 when the downstream line abnormally stopped is used as a trigger. The control device 60 can measure the reference time T1 from the time t0 when the downstream line abnormally stopped, for example, using a timer (not shown), and reduce the sterilization flow rate F when the reference time T1 has elapsed, that is, from approximately the same time as the time t1 when the loading rate R reaches the reference value RV1. This makes it possible to prevent the liquid level L from reaching the upper limit liquid level LV2 and the sterilization device 10 from transitioning to water replacement mode M2 ​​before the filling machine 30 is restarted (step S05), as in the above embodiment. In addition to the above, it is possible to select and discard the configurations given in the above embodiments, or to change them to other configurations as appropriate.

[0062] [Note] The manufacturing line and manufacturing method described above disclose the following. [1] The production line 1 comprises a sterilization device 10 that sterilizes the product liquid, an aseptic tank 20 that receives and stores the product liquid from the sterilization device 10, a sterilization flow rate adjustment unit (12) that is configured to be able to adjust the sterilization flow rate F that corresponds to the flow rate of the product liquid sent to the aseptic tank 20, a filling machine 30 that fills containers with the product liquid supplied from the aseptic tank 20, an accumulation and conveying device 40 that is configured to be able to accumulate containers filled with the product liquid and convey the containers downstream, and a control device 60 that is configured to be able to control at least a part of the production line 1. When the container loading rate R in the storage and transport device 40 increases and reaches a predetermined reference value RV1, the control device 60 reduces the sterilization flow rate F by the sterilization flow rate adjusting section (12). [2] When the filling machine 30 is in operation and the loading rate R increases to reach the reference value RV1, the control device 60 reduces the sterilization flow rate F by the sterilization flow rate adjusting section (12). [3] The control device 60 reduces the sterilization flow rate F from the time when the loading rate R increases and reaches the reference value RV1, through the decrease in the loading rate R, until the loading rate R reaches the lower limit threshold value RT2 corresponding to the restart of the filling machine 30. [4] The control device 60 calculates the loading rate R using the capacity of the storage and transport device 40 and the number of rows of containers. [5] The production line 1 includes a processing device 50 that processes containers downstream of the storage and transport device 40. [6] The control device 60 adjusts the reference value RV1 in accordance with the difference in capacity between the upstream side of the storage and transport device 40 and the downstream side of the storage and transport device 40. [7] When the liquid level L in the aseptic tank 20 reaches the upper limit (LV2), the control device 60 performs a process involving the disposal of the product liquid present in the sterilization device 10. [8] The production line 1 comprises a sterilization device 10 that sterilizes the product liquid, an aseptic tank 20 that receives and stores the product liquid from the sterilization device 10, a sterilization flow rate adjustment unit (12) that is configured to adjust a sterilization flow rate F that corresponds to the flow rate of the product liquid sent to the aseptic tank 20, a filling machine 30 that fills containers with the product liquid supplied from the aseptic tank 20, and a control device 60 that is configured to be able to control at least a part of the production line. When a predetermined reference time T1 has elapsed since an abnormal stop of a processing device 50 that processes containers downstream of the filling machine 30, the control device 60 reduces the sterilization flow rate F using the sterilization flow rate adjustment unit (12). [9] When the liquid level L in the sterile tank 20 reaches the reference liquid level LV1, the control device 60 reduces the sterilization flow rate F by the sterilization flow rate adjusting unit (12).

[10] A manufacturing method using a manufacturing line 1, the manufacturing line 1 comprising at least a sterilization device 10 that sterilizes the product liquid, an aseptic tank 20 that receives and stores the product liquid from the sterilization device 10, a sterilization flow rate adjustment unit (12) configured to be able to adjust the sterilization flow rate F corresponding to the flow rate of the product liquid sent to the aseptic tank 20, a filling machine 30 that fills containers with the product liquid supplied from the aseptic tank 20, an accumulation and conveying device 40 configured to be able to accumulate containers filled with the product liquid and to convey the containers downstream, and a control device 60 configured to be able to control at least a part of the manufacturing line 1. In this manufacturing method, the rise of the liquid level L in the aseptic tank 20 is suppressed by performing either (A) or (B). (A) When a predetermined reference time T1 has elapsed since the processing device 50 that processes containers downstream of the filling machine 30 stopped due to an abnormality, the sterilization flow rate F is reduced by the sterilization flow rate adjusting section (12). (B) In the case where the production line 1 is provided with an accumulation and conveyance device 40 that is configured to be able to accumulate containers filled with product liquid and that conveys the containers downstream, when the container loading rate R in the accumulation and conveyance device 40 increases and reaches a predetermined reference value RV1, the sterilization flow rate F is reduced by the sterilization flow rate adjustment unit (12). [Explanation of symbols]

[0063] 1 production line 10 Sterilizer 11 Cushion Tank 12 Pump device (sterilization flow rate adjustment unit) 13 Heater 14 Heat-retaining tube 15~17 Piping 18 valves 20 Sterile Tank 30 filling machine 31 Discharge conveyor 40 Storage and transport device 41 Transport area 50 Processing equipment 60 Control device 101 Three-way valve 102 Replacement tank 103 Discharge valve 130 Heat source circuit 131,132 flow path 201 Liquid level gauge 401~408 Conveyor equipment C. Circulation Route C1 Sterilization ability C3 filling capacity C4 carrying capacity C5 Processing Power u Upstream d downstream D1 Conveying direction F Sterilization flow rate FF filling flow rate L liquid level L0, L1, L2, L3 liquid level status LV1 Reference liquid level LV2 upper limit liquid level M1 Reduced flow mode M2 Water Displacement Mode P1, P2 inlet ports P3 Exit Port R,r Loading rate R0, R1, R2, R3 Loading rate status RT1 Load factor upper threshold RT2 Load factor lower threshold RV1 Loading ratio standard value S00 Steady operation step S01 Downstream line stop step S02 Sterilization flow rate reduction step S03 Filling machine stop step S04 Downstream line restart step S05 Filling machine restart step s00 Normal operation step s01 Downstream line stop step s02 Filling machine stop step s03 Sterilization flow rate reduction step s04 Downstream line restart step s05 Water replacement mode transition step s06 Filling machine restart step t0 When the downstream line stops t1 When the loading rate increases and reaches the reference value t1-1 When the loading rate reaches the upper threshold corresponding to the stop of the filling machine t2 When the liquid level rises and reaches the reference level t3 When the loading rate reaches the lower threshold T1, T3, T4 Reference times

Claims

1. A manufacturing line, a sterilization device for sterilizing the product liquid; an aseptic tank that receives and stores the liquid product from the sterilizer; a sterilization flow rate adjusting unit configured to adjust a sterilization flow rate corresponding to the flow rate of the product liquid sent to the aseptic tank; a filling machine that fills the liquid product supplied from the aseptic tank into containers; an accumulation and transport device configured to accumulate the containers filled with the liquid product and transport the containers downstream; a control device configured to be able to control at least a part of the manufacturing line, The control device A production line in which, when the loading rate of the containers in the accumulation and conveyance device increases and reaches a predetermined reference value, the sterilization flow rate adjustment unit reduces the sterilization flow rate.

2. The control device When the filling machine is in operation and the loading rate increases to reach the reference value, the sterilization flow rate is reduced by the sterilization flow rate adjusting unit. The manufacturing line according to claim 1 .

3. The control device reducing the sterilization flow rate from when the load rate increases and reaches the reference value, through a decrease in the load rate, until the load rate reaches a lower threshold corresponding to restarting the filling machine; The production line according to claim 1 or 2.

4. the control device calculates the loading rate using the capacity of the storage and transport device and the number of rows of the containers; A manufacturing line according to any one of claims 1 to 3.

5. a processing device for processing the container downstream of the storage and transport device; A manufacturing line according to any one of claims 1 to 4.

6. the control device adjusts the reference value in accordance with a difference in capacity between the upstream side of the storage and transport device and the downstream side of the storage and transport device. A production line according to any one of claims 1 to 5.

7. the control device performs a process involving the disposal of the product liquid present in the sterilization device when the liquid level in the aseptic tank reaches an upper limit. A manufacturing line according to any one of claims 1 to 6.

8. A manufacturing line, a sterilization device for sterilizing the product liquid; an aseptic tank that receives and stores the liquid product from the sterilizer; a sterilization flow rate adjusting unit configured to adjust a sterilization flow rate corresponding to the flow rate of the product liquid sent to the aseptic tank; a filling machine that fills the liquid product supplied from the aseptic tank into containers; a control device configured to be able to control at least a part of the manufacturing line, The control device A production line in which the sterilization flow rate adjustment unit reduces the sterilization flow rate when a predetermined reference time has elapsed since an abnormal stop of a processing device that processes the containers downstream of the filling machine.

9. When the liquid level in the sterile tank reaches a reference liquid level, the control device reduces the sterilization flow rate by the sterilization flow rate adjustment unit. A production line according to any one of claims 1 to 8.

10. A manufacturing method using a manufacturing line, The production line includes at least a sterilization device that sterilizes the product liquid, an aseptic tank that receives and stores the product liquid from the sterilization device, a sterilization flow rate adjustment unit that is configured to be able to adjust a sterilization flow rate corresponding to the flow rate of the product liquid sent to the aseptic tank, a filling machine that fills containers with the product liquid supplied from the aseptic tank, an accumulation and conveyance device that is configured to be able to accumulate the containers filled with the product liquid and convey the containers downstream, and a control device that is configured to be able to control at least a part of the production line, The manufacturing method includes suppressing an increase in the liquid level in the sterile tank by performing either (A) or (B). (A) when a predetermined reference time has elapsed since a processing device that processes the containers downstream of the filling machine stopped due to an abnormality, the sterilization flow rate adjustment unit reduces the sterilization flow rate. (B) if the production line is provided with an accumulation and transport device configured to be able to accumulate the containers filled with the product liquid and transport the containers downstream, when the container loading rate in the accumulation and transport device increases and reaches a predetermined reference value, the sterilization flow rate is reduced by the sterilization flow rate adjustment unit. Manufacturing method.

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