Ambient temperature filling system and method

Abstract

To provide a system and a method for filling a beverage container with a carbonated fluid at ambient temperature while minimizing the formation of foam.SOLUTION: A method comprises retaining treated water in a water tank, deaerating the water tank using a vacuum pump, mixing the treated water with a concentrate to generate a fluid mixture, injecting the fluid mixture with carbon dioxide to generate a carbonated fluid product, storing the carbonated fluid product in a carbonized tank fluidly connected to a filling machine, and operating the filling machine so that a container is filled with the carbonated fluid product, in which the treated water, the fluid mixture, and the carbonated fluid product are maintained at ambient temperature.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Embodiments of the present invention relate to systems and methods for filling a container with a fluid, particularly for filling a beverage container with a carbonated fluid.

Background Art

[0002] The three most common types of liquid filling systems are volumetric filling, time - metered filling, and weight - metered filling (weight filling). All are generally implemented in semi - automatic or automatic filling systems where empty containers are conveyed to a filling position. When the containers reach the filling position, they are stopped, filled to the desired level by a filling head, and then conveyed to the desired location.

[0003] A volumetric filling system (i.e., volumetric metering filling) dispenses a set amount of fluid into a container. For example, a chamber is set to the desired volume, the chamber is filled with fluid, and the contents of the chamber are dispensed into the container.

[0004] A time - metered filling system (i.e., time - metered volumetric filling) dispenses fluid from a nozzle having a known volumetric flow rate for a set amount of time sufficient to fill the container with a set volume of fluid.

[0005] A weight - measuring system (weight measurement) utilizes a weight sensor that monitors the amount of liquid received by the container. The weight sensor provides feedback to the dispensing device, and when the desired weight of fluid has been received, the dispensing device stops dispensing.

[0006] Cryogenic filling operations utilize a refrigeration process to eliminate foaming of carbonated beverages during filling. A large amount of energy is required to cool the carbonated fluid during the refrigeration process. This energy can lead to an increase in operating costs.

Summary of the Invention

[0008] In another embodiment, the filling system can reduce foam formation by eliminating turbulence in the carbon dioxide fluid within the filling system.

[0009] In one aspect of the present invention, a method for producing containers filled with a carbonated fluid product may include: holding treated water in a water tank; degassing the water tank using a vacuum pump; mixing the treated water with a concentrate to produce a fluid mixture; injecting carbon dioxide into the fluid mixture to produce a carbonated fluid product; storing the carbonated fluid product in a carbonization tank fluidly connected to a filling machine; and operating the filling machine to fill containers with the carbonated fluid product. The treated water, fluid mixture, and carbonated fluid product can be maintained at ambient temperature.

[0010] In a further embodiment, a beverage container filling device for filling a beverage container with fluid at ambient temperature may include a support housing having an upper and lower surface defining an inner fluid chamber for supplying fluid material to be discharged into the container; a valve housing mounted on the lower surface for controlling the discharge of fluid material; a vent tube having a first end and a second end, the second end extending at least partially through the valve housing; an umbel ring surrounding the vent tube and positioned adjacent to the second end of the vent tube; a spring positioned around the first end of the vent tube; and a fluid sealing mechanism positioned adjacent to the upper surface and acting together with the spring to control the flow of fluid into the beverage container.

[0011] In another embodiment, a method for producing containers filled with a carbonated fluid product may include: holding treated water at ambient temperature in a water tank; degassing the water tank using a vacuum pump to generate a negative pressure of at least 0.8 bar; mixing the treated water with a concentrate to produce a fluid mixture; injecting carbon dioxide and the fluid mixture at a pressure ranging from about 3.2 bar to about 4.2 bar to produce a carbonated fluid product; storing the carbonated fluid product in a carbonization tank having an internal pressure of about 5.5 bar and being fluidly connected to a filling machine; operating the filling machine having an internal pressure of about 5 bar to fill containers with the carbonated fluid product; and the carbonated fluid product being at ambient temperature. In this method, the filling machine may include a support housing having an upper and lower surface defining an inner fluid chamber for supplying a fluid material to be discharged into a container; a valve housing mounted on the lower surface for controlling the discharge of the fluid material; a vent tube having a first end and a second end, the second end extending at least partially through the valve housing; an umbel inflorescence ring surrounding the vent tube and positioned adjacent to the second end of the vent tube; a spring positioned around the first end of the vent tube; and a fluid sealing mechanism positioned adjacent to the upper surface and acting together with the spring to control the flow of fluid into the beverage container. [Brief explanation of the drawing]

[0012] The accompanying drawings are incorporated into this invention and form part of this specification, illustrating embodiments of the invention, further illustrating the principles of the invention in conjunction with this description, and enabling those skilled in the art to construct and use the invention.

[0013] [Figure 1] This is a schematic diagram of a fluid mixing system based on various embodiments of the present invention.

[0014] [Figure 2] This is a top view of a container filling system according to various embodiments of the present invention.

[0015] [Figure 3]This is a front cross-sectional view of a container filling system according to various embodiments of the present invention.

[0016] [Figure 4] This is a front view of a vent pipe and umbrella ring according to various embodiments of the present invention.

[0017] The features and advantages of the embodiments will become apparent from the detailed description below in conjunction with the drawings, where similar reference numerals throughout the drawings identify corresponding elements. [Modes for carrying out the invention]

[0018] Hereafter, the present invention will be described in detail with reference to embodiments of the present invention as illustrated in the accompanying drawings. References such as "one embodiment," "an embodiment," and "an exemplary embodiment" indicate that the described embodiments may include certain features, structures, or characteristics, but not all embodiments necessarily include certain features, structures, or characteristics. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, where certain features, structures, or characteristics are described in relation to an embodiment, whether explicitly stated or not, any effect on such features, structures, or characteristics in relation to other embodiments shall be known to those skilled in the art.

[0019] Referring to Figure 1, the fluid mixing system 10 may include a treated water tank 100 which is fluidly connected to a treated water source 80. Treated water 102 can flow from the treated water source 80 into the treated water tank 100. The treated water 102 can enter the treated water tank 100 at approximately 17 degrees Celsius. A vacuum pump 110 can remove air and gas from within the treated water tank 100. In one embodiment, the vacuum pump 110 can create a degassing pressure of at least about 0.8 bar within the treated water tank 100. In another embodiment, the degassing pressure within the treated water tank 100 may be about 0.91 bar.

[0020] The treated water pump 104 can pump treated water 102 from the treated water tank 100 to the next stage of the mixing system 10. In one embodiment, the treated water pump 102 can pump the treated water 102 through a cooling system 160 to lower its temperature. In one embodiment, the cooling system 160 can lower the temperature of the treated water 102 from approximately 17 degrees Celsius before it enters the cooling system 160 to approximately 7.6 degrees Celsius after it leaves the cooling system 160. In another embodiment, the treated water 102 can be maintained at ambient temperature within the mixing system 10.

[0021] The mixing system 10 can contain a concentrate 132 in the concentrate tank 130. The concentrate 132 may be a beverage flavor syrup. The treated water 102 can be mixed with the concentrate 132 to form a fluid mixture.

[0022] The carbonization pump 140 can inject carbon dioxide into the fluid mixture in the carbon dioxide dosing device 142 to produce a carbonized fluid mixture, i.e., the product fluid 152. In one embodiment, the injection of carbon dioxide into the carbon dioxide dosing device 142 may occur at a pressure ranging from about 3.2 bar to about 4.2 bar.

[0023] The fluid 152 can be stored in the carbonization tank 150 before being moved to the filling machine 300 for dispensing into containers 400 (Figure 3). In one embodiment, the carbonization tank 150 can be pressurized to about 5.5 bar. In another embodiment, the carbonization tank 150 can be pressurized to about 0.5 bar higher than the filling machine 300.

[0024] Fluid 152 can exit the carbonation tank 150 through the product supply conduit 200 and can enter the product cooling conduit 202 to cool the fluid 152 by passing the fluid 152 through the cooling system 160. In one aspect, the fluid 152 can enter the cooling system 160 at about 11.8 degrees Celsius and can exit the cooling system 160 at about 6.8 degrees Celsius. In another aspect, the carbonation tank 150 can be fluidly connected to the filler 300 so that the fluid 152 can be maintained at ambient temperature within the carbonation tank 150 and within the filler 300.

[0025] In one aspect of the present invention, the process water, fluid mixture, and product fluid 152 can have laminar flow as they move through the mixing system 10. This laminar flow can reduce bubble formation within the fluid 152.

[0026] As shown in FIG. 2, the carousel 206 is part of a filling system for filling the containers 400 with the product fluid 152. The carousel 206 rotates about an axis 208 in the direction of container movement 207. The carousel 206 includes a fluid tank and a product supply pipe (not shown) that extends from the carbonation tank 150 to the corresponding filler 300 (FIG. 3). The filler 300 will be described in more detail below.

[0027] The infeed station 204 is disposed adjacent to the carousel 206 to supply empty containers 400 into the carousel 206. In one aspect, the empty containers 400 can move from a supply station 204 that produces the desired containers 400 from a blower (not shown). The containers 400 can be any suitable type of container, such as cans, jars, or bottles, filled with any type of fluid material, such as carbonated beverages, without departing from the scope of the present invention.

[0028] The infeed station 204 can guide the container 400 into the carousel 206 from a supply source or a plastic blowing system (not shown). In one embodiment, the container 400 enters a pre-washing station before entering the carousel 206, where the container 400 can be washed, rinsed, and sterilized with ionized air, ozone (O3), hydrogen peroxide (H2O2), and / or water.

[0029] The carousel 206 may have positions 210, 220, 230, 240, and 250 in which the container 400 is filled. At position 210, the gas supply source can be opened and the container 400 can be filled with an inert gas, such as carbon dioxide. By filling the container 400 with an inert gas, the pressure in the filling machine 300 can be made equal to the pressure in the bottle. In one embodiment, the pressure inside the filling machine 300 may be about 5 bar. In another embodiment, the pressure inside the filling machine 300 may be about 0.5 bar lower than the pressure inside the carbonization tank 150.

[0030] The container 400 can be moved to position 220 in direction 207. At position 220, the filling machine 300 (Figure 3) can begin filling the container 400 with fluid 152. At position 230, the filling machine can stop filling the container 400 with fluid 152. Also at position 230, the gas supply source can be closed. At position 240, the gas can be released into the atmosphere from the headspace of the container 400 by a process commonly known as "snifting". At position 250, the filling of the container 400 can be terminated.

[0031] An exit station 205 can be positioned adjacent to the carousel 206 to dispense the filled containers 400 from the carousel 206. The exit station 205 can transport the filled containers 400 to a desired location.

[0032] Referring here to Figure 3, the filling machine 300 is shown in more detail. For illustrative purposes, only one filling machine assembly 300 is shown, and it will be understood that multiple filling machines 300 can be arranged around the carousel 206 as the containers 400 move along direction 207 to fill multiple containers 400. The number of filling machines 300 on the carousel 206 may depend on the specific application as desired by the manufacturer. A typical carousel 206 may have as many as 120 filling machines 300 arranged on it. Furthermore, there may be additional pre-cleaning stations and even further post-cleaning stations oriented around the carousel 206.

[0033] The filling machine 300 may include a support housing 302 having an upper surface 304 and a lower surface 306 that define an inner fluid chamber 310 for supplying a fluid 152 to be discharged into a corresponding container 400. The fluid 152, preferably a liquid beverage, can fill a portion of the fluid chamber 310 while leaving headspace 320 above the fluid 152 for a pressurized inert gas such as carbon dioxide or nitrogen. These drawings also do not show supply and return pipes for the fluid 152 and gas.

[0034] A valve housing 330 can be mounted on the lower surface 306 of the support housing 302 to control the discharge of fluid 152 into the container 400. The valve housing 330 is schematically shown in the drawings and may be of any suitable design or configuration. An annular container seal 332 can be provided within the valve housing 330 to engage with the container 400 in a sealing manner. In the embodiment shown in Figure 3, the container seal 332 can be designed to seal a bottle-type container 400. In another embodiment, the container seal 332 may be configured to receive a can. A control device 340 can be positioned adjacent to the upper surface 304 of the support housing 302. The control device 340 will be described in more detail below.

[0035] The vent pipe 312 may have a first end 313a and a second end 313b, the second end 313b extending at least partially through the valve housing 330. The vent pipe 312 may have a height of less than about 4.5 mm. The vent pipe 312 may have an umbel ring 316 (Figure 4) positioned adjacent to the second end 313b. The umbel ring 316 may have a diameter 317.

[0036] The vent tube 312 can move along a predetermined stroke between a filled position and an unused position. The second end 313b of the vent tube 312 and the umbel inflorescence ring 316 can be positioned inside the container 400 while in the filled position, and the second end 313b of the vent tube 312 can be raised above the container 400 while in the unused position. When the vent tube 312 is in the filled position, the umbel inflorescence ring 316 can be centered in the X and Y directions relative to the container 400.

[0037] The vent pipe 312 can also move according to the desired filling level in the container 400 of different sizes. The overall range of the stroke of the vent pipe 312 can be adjusted and depends on the type and size of the container 400 being filled. To vent gas from the container 400 into the fluid chamber 310 during the filling of the container 400, the vent pipe 312 can be in fluid communication with the headspace 320 of the inner fluid chamber 310.

[0038] The support pipe 314 can be installed between the upper surface 304 and the lower surface 306 of the support housing 302 and can substantially enclose the vent pipe 312. In one embodiment, the support housing 302 can enclose the central portion of the vent pipe 312, and the ends of the first end 313a and the second end 313b are not enclosed by the support pipe 314. Multiple sealing portions (not shown) can be included between the vent pipe 312 and the support pipe 314 in order to support the vent pipe 312 within the support housing 302.

[0039] The fluid sealing mechanism 322, including the spring 318, can be movably mounted relative to the support tube 314 to control the discharge of fluid 152 from the inner fluid chamber 310 to the container 400. The length of the spring 318 can be shortened to slow the movement of the valve. In one embodiment, the spring strength can be optimized for laminar flow of fluid 152 from the filling machine 300 into the container 400. The angle of the valve mounting surface can also be adjusted.

[0040] The operating lever 341 can be mounted within the support housing 302 and can engage with the fluid sealing mechanism 322 to operate the mechanism 322 between an open position that releases fluid 152 through the valve housing 330 and a closed position that seals the fluid chamber 310 of the support housing 302 from the valve housing 330. The fluid sealing mechanism 322 and the operating lever 341 may utilize several additional components to achieve their operation.

[0041] The filling machine 300 may include a snifting pipe 352 and a snifting valve 353 for releasing gas from the headspace of the container 400 to the atmosphere when the container 400 is at position 240 on the carousel 206. In one embodiment, the diameter of the snifting pipe 352 can be about 1.5 mm smaller than that of a conventional snifting pipe. The snifting pipe 352 may have a diameter greater than about 1.5 mm. In one embodiment, snifting of the container 400 may occur in two stages in response to foaming of the fluid 152 inside the container 400. The filling machine 300 may also include a pressure release pipe 356 and a pressure release valve 357.

[0042] The general filling operation of the filling machine 300 is described below. The fluid 152 can have a laminar flow through the filling machine 300. In another embodiment, the fluid 152 can be filled from the filling machine 300 into the container 400 at ambient temperature, for example, about 15 degrees Celsius. Ambient filling requires less cooling and can significantly reduce operating costs.

[0043] The fluid sealing mechanism 322 can be closed first, raising the vent pipe 312. Atmospheric pressure spreads inside the vent pipe 312. The empty container 400 moves to one of the lower positions of the valve housing 330 of the carousel 206. The container 400 can then be moved to engage with the container sealing portion 332 on the valve housing 330, and the vent pipe 312 can be lowered to the filled position. The container 400 can be purged with an inert gas from the inner fluid chamber 310 through the vent pipe 312 to flush out air and other impurities from the container 400. The operating lever 341 can be actuated to raise the fluid sealing mechanism 322 to the open position. While the inert gas inside the container 400 vents through the vent pipe 312 into the headspace 320 of the inner fluid chamber 310, the fluid 152 can be allowed to flow from the inner fluid chamber 310 into the container 400. The gas pressure in the container 400 and the inner fluid chamber 310 can be made the same during the filling process, thereby allowing the fluid 152 to flow into the container 400 under the sole influence of gravity. The container 400 can continue to fill until the liquid rises to the height of the second end 313b of the vent pipe 312. The filling level in the container 400 can be determined by the lower position of the second end 313b of the vent pipe 312. Once the fluid 152 reaches the vent pipe 312, the gas can no longer escape through the vent pipe 312, and therefore the fluid can no longer flow into the container 400. After the container 400 has been filled to the desired level, the actuation lever 341 can be actuated to move the fluid sealing mechanism 322 to the closed position, where the fluid sealing mechanism 322 engages with the valve housing 330 in a sealing manner. The vent pipe 312 can then be raised from the container 400 to the unused position. Finally, the gas can be released into the atmosphere from the top of the container 400.

[0044] A cryogenic fill system can dispense fluid at approximately 8 degrees Celsius into a container. In one aspect of the present invention, fluid 152 can be dispensed into container 400 at approximately 15 degrees Celsius, resulting in significant energy savings. A filling system according to the present invention that fills container 400 with fluid at approximately 15 degrees Celsius can reduce the system energy required to cool the fluid by approximately 60% compared to a cryogenic fill system that fills at approximately 8 degrees Celsius.

[0045] It should be understood that the "Modes for Carrying Out the Invention" section, rather than the "Summary of the Invention" and "Abstract" sections, is intended to be used to interpret the claims. The "Summary of the Invention" and "Abstract" sections may illustrate one or more, but not all, exemplary embodiments of the Invention as conceived by the inventors(s), but are not intended to limit the Invention and the attached "Claims" in any way.

[0046] The present invention(s) have been described so far using functional components that exemplify the implementation of specific functions and their relationships. The boundaries of these functional building blocks are arbitrarily defined herein for the sake of explanation. Alternative boundaries can be defined, as long as the specific functions and their relationships are adequately performed.

[0047] The above description of specific embodiments fully reveals the general nature of the present invention, and others can readily modify and / or adapt such specific embodiments to various uses without excessive trial and error and without departing from the general concept of the present invention by applying the knowledge of those skilled in the art. Therefore, such adaptations and modifications are intended to be within the meaning and scope of the equivalents of the disclosed embodiments, based on the teachings and guidance presented herein. It should be understood that the expressions and terminology herein are for illustrative purposes only and not limiting, and therefore, the terms and expressions herein should be interpreted by those skilled in the art in terms of teachings and guidance.

[0048] The breadth and scope of the present invention should not be limited by any of the exemplary embodiments described above, but should be defined solely by the following "Claims" and their equivalents.

Claims

1. A carbonization tank filled with a carbon dioxide fluid at ambient temperature, A beverage container filling device, A carousel having at least one product supply conduit extending from the carbonization tank to the beverage container filling device, The carousel is equipped with a gas supply source connected to it. The carousel is configured to rotate from a first position to a second position. The gas supply source is configured to fill the container with inert gas when the carousel is rotated to the first position. The beverage container filling device is configured to fill the container with the carbonated fluid when the carousel is rotated to the second position. A beverage container filling system in which the carbon dioxide fluid at ambient temperature is maintained at ambient temperature during the operation of the beverage container filling device.

2. The beverage container filling system according to claim 1, wherein the carousel is further configured to rotate from the second position to the third position, from the third position to the fourth position, and from the fourth position to the fifth position.

3. The beverage container filling system according to claim 2, wherein the gas supply source is configured to close when the carousel is rotated to the third position.

4. The beverage container filling system according to claim 2, wherein when the carousel is rotated to the third position, the beverage container filling device is configured to stop filling the container with the ambient temperature carbonated fluid.

5. The beverage container filling device has a snifting pipe, The beverage container filling system according to claim 2, wherein when the carousel is rotated to the fourth position, the snifting pipe is configured to release the inert gas from the headspace of the container.

6. The beverage container filling system according to claim 1, wherein the ambient temperature is approximately 15 degrees Celsius.

7. The carousel has an exit station located adjacent to it, The beverage container filling system according to claim 1, wherein the outlet station is configured to send filled containers from the carousel to a predetermined position.

8. A carbonization tank filled with fluid at ambient temperature, A beverage container filling device, A support housing having an upper and lower surface that defines an inner fluid chamber for supplying the carbon dioxide fluid at ambient temperature to be discharged into the container, A valve housing provided on the lower surface for controlling the discharge of the fluid, A vent pipe having a first end and a second end, wherein the second end extends at least partially through the valve housing, An umbel inflorescence ring surrounds the aforementioned ventilator and is positioned adjacent to the second end of the aforementioned ventilator, A spring is positioned around the first end of the vent pipe, A beverage container filling device comprising: a fluid sealing mechanism positioned adjacent to the upper surface and acting together with the spring to control the flow of the ambient temperature carbonated fluid into the beverage container; A carousel having at least one product supply conduit extending from the carbonization tank to the beverage container filling device, The carousel is equipped with a gas supply source connected to it. The carousel is configured to rotate from a first position to a second position. The gas supply source is configured to fill the container with inert gas when the carousel is rotated to the first position. The beverage container filling device is configured to fill the container with a carbonated fluid at the ambient temperature when the carousel is rotated to the second position. A beverage container filling system in which the carbon dioxide fluid at ambient temperature is maintained at ambient temperature during the operation of the beverage container filling device.

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