Filling machine equipped with a sterilization station

Abstract

A filling machine (10) is provided that is configured to form, fill, and seal individual packages (4). The filling machine includes a sterilization station (100) configured to direct a stream of gaseous sterilant toward the open ends of ready-to-fill packaging containers (4) passing through the sterilization station (100). The filling machine includes at least one clean air supply (150) and at least one baffle plate (138) disposed in the at least one clean air supply, the air supply (150) configured to direct a stream of clean air toward the ready-to-fill packaging containers (4), the clean air supply (150) similarly including at least one distribution pipe (150) that extends horizontally, the horizontal direction being the direction of flow of the packages through the filling machine (10).

Description

Technical Field

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

Background Art

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

[0003] One common type of package is the so-called ready-to-fill package. Such ready-to-fill packages are provided as sleeves of a packaging laminate such as those described above, with the bottom end of the sleeve sealed before filling. The upper end can be formed either by forming and sealing the upper end of the sleeve or by making the upper part, for example in the form of a polymer top; the upper end / part may be provided with opening / closing means, such as a screw cap.

[0004] Another type of package that can be used together with the present invention described herein is produced in an upside-down configuration where the top part (arranged downward) is sealed and the bottom part is open for filling. Generally, the top part arranged downward is produced as a polymer top.

[0005] Regardless of the type of package being produced, an open-ended packaging material sleeve is received at the feeding station of the filling machine, and then one end of the sleeve is sealed; the semi-finished package at this point has a shape that allows for immediate filling. However, further processes are required to achieve hygienic packaging. At a downstream station, the open-ended sleeve is sterilized, at least on the inside, to extend the shelf life of the product stored in the package. Different levels of sterilization can be achieved depending on the desired shelf life, and depending on whether the package is distributed and stored in a refrigerated storage environment or at room temperature. Sterilization is carried out using a gaseous sterilization agent, such as H2O2.

[0006] After sterilization, the packages are further transported to a filling zone for product filling, a sealing zone for sealing the open ends, and typically, a final forming zone for the final formation of the package.

[0007] The transport of packages is achieved by a series of carriers guided along a transport route. Preferably, the transport route runs continuously through a filling machine, so that incoming packages move through the filling machine and all necessary stations.

[0008] After sterilization of ready-to-fill packages, maintaining hygiene is crucial because the packages are filled and sealed by subsequent stations. Therefore, these stations in the filling machine are located in a hygienic zone to ensure minimal re-contamination of already sterilized packages.

[0009] In the filling machine described above, the transport system for ready-to-fill packages in the sanitary chamber is kept at a relatively low temperature due to i) the low temperature environment in the sanitary chamber and ii) the use of cooling water to lubricate the transport system.

[0010] During the sterilization process, the dew point of H2O2 gas needs to be very high to ensure condensation of H2O2 across the entire inner surface of the ready-to-fill package. As a result, the high dew point of the gas also produces a considerable amount of condensed H2O2 on the transport system as well as on the outer surface of the package.

[0011] Therefore, condensed H2O2 on the transport system and on the outer surface of the package is transported through the filling machine. The condensed film slowly evaporates as it moves through the entire transport system, and the release of H2O2 occurs from the openings of the filling machine; from the feed openings through which the blanks are fed into the filling machine; and from the outfeed openings through which the formed, filled, and sealed packages are sent out of the filling machine.

[0012] Furthermore, this will generate considerable concentrations of H2O2 throughout the filling machine, and even in areas where mechanical parts not specifically designed to withstand H2O2 exposure may exist. This could, for example, corrode or shorten the lifespan of such parts.

[0013] Another issue relates to machine downtime. While the machine is stopped, access to the filling machine should preferably not be permitted until the H2O2 has evaporated and the area has been ventilated, resulting in a delay.

[0014] Given the aforementioned drawbacks associated with the use of sterilizing agents such as gaseous agents like H2O2, it is necessary to reduce the condensation of H2O2 in the transport system and on the outer surface of the package during the sterilization process, while still maintaining a controlled and sufficiently high concentration of the sterilizing agent inside the package. [Overview of the Initiative] [Problems that the invention aims to solve]

[0015] The object of the present invention is to overcome, at least in part, one or more of the limitations of the prior art identified above. In particular, the object is to provide a filling machine that can ensure the necessary sterilization of ready-to-fill packages while reducing unwanted condensation and evaporation of gaseous sterilizers. [Means for solving the problem]

[0016] To address these objectives, a filling machine is provided. The filling machine is configured to form, fill, and seal individual packages, thereby including a sterilization station, which is configured to bring a flow of gaseous sterilizer toward the open end of a ready-to-fill packaging container passing through the sterilization station. The filling machine further includes at least one clean air supply unit, which is positioned vertically below the open end of the ready-to-fill packaging container and is configured to direct a stream of clean air, preferably filtered or sterile air, toward the ready-to-fill packaging container. Preferably, the clean air supply unit extends in the direction of the machine across the location of one or more gaseous sterilizer supply units.

[0017] The clean air supply unit may include at least one distribution pipe, thereby effectively distributing the clean air.

[0018] The distribution pipes may extend horizontally, and the horizontal direction is the direction of the package flow through the filling machine.

[0019] The distribution pipe may have multiple outlet holes distributed along its longitudinal direction. The outlet holes are oriented upward and inward toward the ready-to-fill packaging containers.

[0020] The filling machine may further include at least one baffle plate positioned vertically above at least one clean air supply unit. Preferably, a baffle plate positioned horizontally is advantageous because several jets of clean air merge into a planar jet. The baffle plate also physically separates the gaseous environment above the baffle plate from the clean air environment below the baffle plate, thus avoiding mixing of the two. Thus, dilution of the gas above the baffle plate is avoided, and therefore it is possible to maintain a high concentration of gas around the gas jet, i.e., the gas supply unit, and the jet, and therefore the gas in the package, is not diluted. Part of this is described in rows 14-17 of side 6, but here the plate is important.

[0021] Furthermore, the clean air jet is directed towards the baffle plate, achieving so-called "wall adhesion," thereby generating wall jets. These wall jets act as rectangular jet-like structures on the baffle plate, thereby protecting the openings between the baffle plates. This protection of the openings reduces the vertical gas flow from the gas supply nozzle and thereby directs more of the horizontal gas flow towards the downstream holding section, thereby helping to maintain the package in the gaseous environment.

[0022] It has been found that when the gas flow perpendicular to the baffle plates is small, it concentrates more on the central plane, thereby preventing the flow around the wider portion of the package carrier surface from being diluted by the clean air flow and resulting in high concentrations of gas in those areas.

[0023] The filling machine may include a first distribution pipe located on one side of the ready-to-fill package and a second distribution pipe located on the opposite side of the ready-to-fill package.

[0024] The clean air supply may preferably be configured by a baffle plate to provide a planar jet of clean air towards the ready-to-fill package.

[0025] The filling machine may include a plurality of indexing positions for supplying a gaseous sterilizing agent to a plurality of ready-to-fill packages, and the clean air supply in the form of one or more distribution pipes extends across the indexing positions.

[0026] The clean air supply may be connected to an air supply system for downstream ventilation means.

[0027] According to a second aspect, a method for sterilizing a ready-to-fill package is provided. The method includes a first step of supplying a gaseous sterilizing agent towards the inside of the ready-to-fill package, and a second step of providing a flow of clean air, preferably filtered and / or sterile air, towards the outer surface of the ready-to-fill package.

[0028] The step of providing a flow of clean air towards the outer surface of the ready-to-fill package may include directing a plurality of clean air jets towards a baffle plate to provide a planar jet of clean air.

[0029] Still other objects, features, aspects and advantages of the present invention will become apparent from the following detailed description and the drawings.

[0030] Here, embodiments of the present invention will be described by way of example with reference to the accompanying schematic diagrams.

Brief Description of the Drawings

[0031] [Figure 1] It is a schematic diagram of a filling machine according to an embodiment. [Figure 2] It is a schematic isometric view of a sterilization station forming part of a filling machine according to an embodiment. [Figure 3] [[ID= [Figure 4] This is a schematic isometric view of a distribution pipe forming part of a filling machine according to one embodiment. [Figure 5] This is a schematic diagram of a method according to one embodiment. [Figure 6a-c] This is a simulation graph of a sterilization station forming part of a filling machine according to one embodiment during operation. [Modes for carrying out the invention]

[0032] Referring to Figure 1, the filling machine 10 is schematically shown. The filling machine described in the following text is configured to produce carton-based packages by closing the bottom end of a tube of packaging material and, after sterilization and filling, finally closing its top end. However, the filling machine 10 may also be configured to produce other types of packages, such as plastic top packages, which are briefly described in the background art of this application.

[0033] A filling machine 10 configured to form, fill, and seal packages 4 has a feeding station 12 from which blank packaging material 2 is received. The blanks 2 are generally produced as sleeves of carton-based packaging material, as is well known in the industry and has already been briefly described in the background art. The feeding station 12 is located upstream of a bottom sealing station 14, where the blanks 2 are upright in a tubular shape, and at the bottom sealing station 14, the bottom end of each blank is sealed and closed to form a semi-finished package, while the top end of the package remains open.

[0034] The semi-finished packages are transported to sterilization station 100, where the amount of living microorganisms is reduced. As described in the background technology section, the sterilization level can vary depending on the user's purpose. Sterilization of the packaging material is achieved by treatment using a gaseous sterilizer, preferably H2O2 (hydrogen peroxide).

[0035] The sterilization station 100 includes an upstream supply station 110, which provides the flow of gaseous sterilizing agent. An aeration station 120 is located downstream of the supply station 110.

[0036] A sanitary room is provided downstream of the sterilization station 100. The sanitary room includes further stations for the filling machine. Immediately downstream of the sterilization station 100 is the filling station 30, where ready-to-fill packages are filled with the desired product contents. After filling, the packages may be transported to a pre-folding station 32, where the upper portion of the open package is formed into the desired shape. After pre-forming, the packages are transported to a heating station 34, where the heat-sealable material of the packaging material is heated to a high temperature. The high temperature of the upper end of the package facilitates the sealing of the upper end when the package enters the sealing station 36, which is located immediately after the heating station 34.

[0037] Once sealed, package 4 no longer requires sanitary conditions when leaving the sanitary room. A discharge station 16 is located at the end of the filling machine 10, and the discharge station is configured to send the completed package 4 from the filling machine 10 to downstream equipment for storage and / or transport.

[0038] The sterilization station 100 is further shown in Figure 2. As shown in the drawing, the sterilization station 100 has a tunnel shape. Ready-to-fill packages (not shown) are sent into the sterilization station 100 from the left side of the drawing. The ready-to-fill packages are transported by a conveyor containing multiple continuous cassettes; each cassette carries a ready-to-fill package. For illustrative purposes, the conveyor, as well as the cassettes and the packaging containers contained therein, are not shown (these mechanical parts may be shown in Figure 3).

[0039] This type of conveyor, including cassettes, is well known in the industry and will not be described further in this specification.

[0040] As shown in Figure 2, the sterilization station 100 is equipped with multiple baffle plates 132. Two vertical baffle plates 132 are located on the inlet side of the sterilization unit 100 and extend from the bottom to the top of the tunnel. The baffle plates 132 are separated in the machine direction, and the space between these baffle plates 132 functions as the inlet section 134 of the sterilization station 100.

[0041] A supply section 110 is located downstream of the inlet section 134. The purpose of the supply section 110 is to provide a flow of gaseous sterilizer, preferably H2O2, to sterilize the inner and outer surfaces of the ready-to-fill package. As described above in the background art, the dew point of H2O2 gas ensures condensation of H2O2 on the inner surface of the ready-to-fill package.

[0042] The sterilization station 100, and in particular the supply section 110, is preferably provided as a continuous tunnel, where a high and relatively uniform concentration of gaseous sterilizing agent is generated in the vertically upward gas processing section to establish a controlled and uniform gas distribution within the package and obtain the required sterilization effect. As described below, this is achieved without causing large amounts of condensation on the conveyor in the vertically downward section.

[0043] A vertical baffle plate 136 is provided in the upper portion of the supply section 110. The baffle plate 136 of the supply section 110 extends upward from a horizontally positioned baffle plate 138. The horizontal baffle plates 138 are spaced apart to allow cassettes and ready-to-fill packages to pass between them.

[0044] The vertical baffle plate 136 of the supply section 110 divides the space within the tunnel into four distinct indicator positions. In a preferred embodiment, each indicator position is associated with a gas supply tube 140 preferably located longitudinally on the vertical baffle plate 136. Thus, four ready-to-fill packages are positioned simultaneously at their indicator positions, thereby activating the gas supply tube 140 to supply gaseous disinfectant toward the interior of the ready-to-fill packages. However, in some embodiments, one or more of the gas supply tubes 140 may be replaced, for example, by a gas holding station, i.e., no gas supply is provided at this position. To reduce the amount of disinfectant on the conveyor, distribution pipes 150 are provided. These distribution pipes 150 will be further described with reference to Figure 3.

[0045] Referring again to Figure 2, immediately downstream of the indicator position is a holding section 112; here, condensation can take place for a certain period of time.

[0046] In another embodiment, H2O2 is used as a sterilizing agent in conjunction with a UV light source located in a downstream holding section 112. Thus, the initial gas concentration can be as low as 3% H2O2 in this modification, for example, compared to 35% H2O2, but the dew point of the gas is much higher, and the amount of condensation is considerably increased compared to the case of 35% H2O2.

[0047] The ventilation station 120 is located downstream of the holding section 112 for the purpose of evaporating all sterile agents from the ready-to-fill package.

[0048] Referring now to Figure 3, a cross-section of the supply section 110 is shown. The ready-to-fill package 4 is carried by a cassette 5 that extends along most of the entire vertical extension of the ready-to-fill package 4. The cassette 5 is then driven by a conveyor (not shown) connected to the bottom of the cassette 5.

[0049] The gas supply tube 140 is positioned downwards so that the sterilizing agent can enter the ready-to-fill package 4 and sterilize its interior. Some of the sterilizing agent also condenses on the outer surface of the package 4 and in the cassette. Distribution pipes 150, positioned on each side of the cassette 5 and extending horizontally, i.e., in the direction of the package flow through the filling machine, help reduce the amount of sterilizing agent on the cassette 5 and on the conveyor. Distribution pipes 150 form a clean air supply section, which extends horizontally at a vertical position below the open end of the ready-to-fill packaging container and is configured to direct a stream of clean air, preferably filtered and / or sterile air, towards the packaging container.

[0050] The idea is to introduce two clean air supply pipes 150, one on each side of the conveyor / cassette 5, which extend horizontally and are positioned slightly below the horizontal baffle plate 138 in a vertical direction, that is, perpendicular to the flow of packages through the filling machine. These branch pipes 150 are designed to have a row of outlet holes 152 (see Figure 4). The distance between the branch pipes 150 and the associated baffle plate 138 positioned vertically above the branch pipes 150 is in the range of 2 to 100 mm.

[0051] The distribution pipe 150 extends along the indicator position so that the four cassettes 5 are simultaneously exposed to clean air.

[0052] Further details of the distribution pipe 150 are shown in Figure 4. Typical dimensions of the outlet hole 152 may include a diameter of 4 mm and a center-to-center distance of 12 mm, but other dimensions are also possible.

[0053] The outlet hole 152 is positioned at an angle toward the horizontal baffle plate 138 (see Figure 3), thereby creating a planar jet along the direction of package movement, the conveyor, and the outer surface of the package, as indicated by the arrows in Figure 3. This planar jet of clean air reduces the concentration of sterilizing agents, such as H2O2, near the conveyor and the outer surface of the ready-to-fill packaging container without affecting the uniform and high concentration of gas present above the horizontal baffle plate 138.

[0054] The introduced airflow may be very small. This is because the inlet air jet draws air from the lower part of the tunnel of the supply section 110, thereby further enhancing the dilution effect of the gas. This also means that because the velocity of the planar air jet created is very slow, a highly controlled concentration can be maintained in the upper part of the supply section 110.

[0055] The supply of clean air for the distribution pipe 150 may preferably be integrated with the air supply system for the ventilation means 122. Two benefits are obtained when the heater is branched after it is connected to the air supply system. Firstly, since the clean air is relatively warm, this also contributes to further enhancing the heating of the horizontal baffle plate 138, as well as the evaporation of the condensation film on the cassette 5 and on the outer surface of the packaging container 4. This improves the robustness of the system and also helps maintain sanitary conditions within the piping system.

[0056] Referring here to Figure 5, a method 200 for sterilizing the ready-to-fill package 4 is schematically shown. Method 200 includes a first step 202 of supplying a gaseous sterilizer toward the interior of the ready-to-fill package, and a second step 204 of bringing a flow of clean air toward the outer surface of the ready-to-fill package 4. Preferably, step 204 of bringing a flow of clean air toward the outer surface of the ready-to-fill package 4 includes directing multiple clean air jets toward the baffle plate 138 to bring a planar jet of clean air.

[0057] Referring to Figures 6a-c, a simulated filling machine 10 is shown, in which a gaseous sterilizing agent, in this case H2O2, is supplied toward the open ends of a series of ready-to-fill packages 4. Each ready-to-fill package 4 is carried by a cassette 5 as described above. As shown in Figure 6a, sterilization occurs at four indicator positions.

[0058] Figure 6a shows that the sterilizing agent is concentrated inside the ready-to-fill package 4, compared to the simulation in Figure 6c where the sterilizing agent leaks and is distributed around the ready-to-fill package 4. The difference between the filling machine 10 in Figure 6a and the machine in Figure 6c is that in Figure 6a, a clean air supply section in the form of two distribution pipes 150 directs a jet of clean air towards the ready-to-fill package 4.

[0059] Figure 6b shows a cross-sectional view of the filling machine 10 in Figure 6a, further illustrating the effect of the distribution pipe 150.

[0060] Although various embodiments of the present invention have been described and illustrated above, the present invention is not limited thereto and may be provided in other ways within the scope of the subject matter defined in the following claims.

Claims

1. A filling machine (10) configured to form, fill and seal individual packages (4), comprising a sterilization station (100), the sterilization station configured to bring a flow of gaseous sterilizing agent toward the open end of an immediately fillable package (4) passing through the sterilization station (100), The aforementioned filling machine further, A conveyor equipped with a cassette (5), the cassette (5) transports the ready-to-fill package (4), At least one clean air supply unit (150) and It includes a plurality of baffle plates (138) positioned above the at least one clean air supply unit (150), The at least one clean air supply unit (150) is configured to direct the clean air toward the ready-to-fill package (4), The at least one clean air supply unit (150) includes at least one distribution pipe (150), and the at least one distribution pipe (150) extends horizontally, the horizontal direction being the direction of the flow of the ready-to-fill packages (4) through the filling machine (10), The cassette (5) and the ready-to-fill package (4) pass between the plurality of baffle plates (138) that are spaced apart in a direction intersecting the horizontal direction. filling machine.

2. The filling machine according to claim 1, wherein the at least one distribution pipe (150) comprises a plurality of outlet holes (152) distributed in the longitudinal direction of the distribution pipe (150).

3. The filling machine according to claim 2, wherein the outlet hole (152) is directed upward and inward toward the ready-to-fill package (4).

4. The filling machine according to any one of claims 1 to 3, wherein the at least one distribution pipe (150) includes a first distribution pipe (150) located on one side of the ready-to-fill package (4) and a second distribution pipe (150) located on the opposite side of the ready-to-fill package (4).

5. The filling machine according to any one of claims 1 to 4, wherein the at least one clean air supply unit (15) comprises a plurality of distribution pipes (150), and the plurality of distribution pipes (150) are configured to direct a plurality of clean airs to the plurality of baffle plates (138).

6. A filling machine according to any one of claims 1 to 5, comprising a plurality of indicator positions for supplying a gaseous sterilizing agent to a plurality of ready-to-fill packages (4), wherein at least one clean air supply unit in the form of one or more distribution pipes (150) extends across the indicator positions.

7. The filling machine according to any one of claims 1 to 6, wherein the at least one clean air supply unit (150) is integrated with an air supply system for ventilation means (122).

8. A method for sterilizing a ready-to-fill package (4), comprising supplying a gaseous sterilizing agent toward the interior of the ready-to-fill package (4) (202), and providing a flow of clean air toward the outer surface of the ready-to-fill package (4) (204), wherein providing the flow of clean air toward the outer surface of the ready-to-fill package (4) (204) includes directing a plurality of clean air streams toward a plurality of baffle plates (138), A cassette for transporting the ready-to-fill packages (4) and the ready-to-fill packages (4) passing between a plurality of baffle plates (138) spaced apart in a direction intersecting the horizontal direction, wherein the horizontal direction is the direction of flow of the ready-to-fill packages (4). method.

9. The first distribution pipe (150) and the second distribution pipe extend in the horizontal direction and are positioned below the plurality of baffle plates (138). The filling machine according to claim 4.

10. The outlet hole (152) is positioned at an angle toward the plurality of baffle plates (138). The filling machine according to claim 2.

11. A filling machine (10) configured to form, fill, and seal individual packages (4), A feeding station (12) that receives blank packaging material (2), A bottom sealing station (14) forms a ready-to-fill package (4) having an open end by shaping the blank packaging material (2) into a tube shape and sealing one end of the tube shape to form a bottom end, A sterilization station (100) is configured to direct the flow of gaseous sterilizing agent toward the open end of the ready-to-fill package (4), A filling station (30) fills the desired product contents into the ready-to-fill package (4) after sterilization, A pre-folding station (32) that forms the open end of the immediately fillable package (4) into a desired shape after filling, A heating station (34) for heating the heat-sealable material of the packaging material (2), A sealing station (36) that seals the open end of the immediately fillable package (4) after heating to form a completed package (4), A dispatch station (16) that sends out the completed package (4), Equipped with, The sterilization station (100) is A conveyor comprising multiple cassettes (5), wherein the cassettes (5) transport the ready-to-fill packages (4), A first horizontal baffle plate (138) extending in the horizontal direction which is the flow direction of the ready-to-fill package (4), The second horizontal baffle plate (138) extending in the horizontal direction, A first distribution pipe (150) extends horizontally, is located on one side of the ready-to-fill package (4), and is positioned below the first horizontal baffle plate (138), A second distribution pipe (150) extends horizontally, is located below the second horizontal baffle plate (138), and is located on the other side of the ready-to-fill package (4), Equipped with, The first distribution pipe (150) comprises a first plurality of outlet holes (152) distributed in the longitudinal direction of the first distribution pipe, and the first plurality of outlet holes are configured to direct clean air toward the first horizontal baffle plate (138). The second distribution pipe (150) comprises a second plurality of outlet holes (152) distributed in the longitudinal direction of the second distribution pipe, and the second plurality of outlet holes are configured to direct the clean air toward the second horizontal baffle plate (138). The cassette (5) and the ready-to-fill package (4) pass between the first horizontal baffle plate (138) and the second horizontal baffle plate (138). filling machine.

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