Blow molding system, content filling system, blow molding method, and content filling method

Abstract

To provide a blow molding system, a content filling system, a blow molding method and a content filling method that are capable of reducing an environmental load of the blow molding system while maintaining high effect of sterilizing a container.SOLUTION: A blow molding system 10 comprises: an injection molding unit 11 that produces a preform 51 by injection molding; a temperature adjustment unit 12 that adjusts a temperature of the preform 51 produced by the injection molding unit 11; a blow molding unit 16 that produces a container 52 by blow-molding the preform 51 the temperature of which has been adjusted by the temperature adjustment unit 12; and a first sterilization unit 17 that sterilizes the container 52 produced by the blow molding unit 16. A surface temperature of at least a part of the container 52 and the preform 51 is maintained at or above 40°C from the injection molding unit 11 to the first sterilization unit 17.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a blow molding system, a content filling system, a blow molding method, and a content filling method.

Background Art

[0002] There is known a content filling system in which sterilized contents are filled into a sterilized container in a sterile environment and then the container is sealed with a cap. Specifically, in the content filling system, a formed container is supplied to the content filling system, and in the content filling system, an aqueous hydrogen peroxide solution as a bactericide is sprayed onto the container. Then, the container is filled with the contents.

[0003] By the way, in recent years, there has been a demand to reduce the environmental load of the content filling system.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The present disclosure provides a blow molding system, a content filling system, a blow molding method, and a content filling method capable of reducing the environmental load of the blow molding system while maintaining a high sterilization effect on the container.

Means for Solving the Problems

[0006] The blow molding system according to this embodiment comprises an injection molding unit for producing a preform by injection molding, a temperature adjustment unit for adjusting the temperature of the preform produced by the injection molding unit, a blow molding unit for producing a container by blow molding the preform whose temperature has been adjusted by the temperature adjustment unit, and a first sterilization unit for sterilizing the container produced by the blow molding unit, wherein the surface temperature of at least a portion of the preform and the container is maintained at 40°C or higher from the injection molding unit to the first sterilization unit.

[0007] In the blow molding system according to this embodiment, the temperature control unit includes a cooling unit for cooling the preform and a heating unit for heating the preform cooled by the cooling unit, and a second sterilization unit for sterilizing the preform may be provided between the cooling unit and the heating unit.

[0008] In the blow molding system according to this embodiment, the temperature control unit may have a cooling unit for cooling the preform, but may not have a heating unit for heating the preform.

[0009] In the blow molding system according to this embodiment, the injection molding unit, the temperature control unit, the blow molding unit, and the first sterilization unit may be controlled by the same control unit.

[0010] The contents filling system according to this embodiment comprises a blow molding system according to this embodiment and a filling device for filling the container with contents.

[0011] The blow molding method according to this embodiment comprises the steps of: producing a preform by injection molding; adjusting the temperature of the preform; producing a container by blow molding the temperature-adjusted preform; and sterilizing the container, wherein the surface temperature of at least a portion of the preform and the container is maintained at 40°C or higher from the time the preform is produced by injection molding until the container is sterilized.

[0012] In the blow molding method according to this embodiment, the step of adjusting the temperature of the preform includes a step of cooling the preform and a step of heating the cooled preform, and a step of sterilizing the preform may be provided between the cooling step and the heating step.

[0013] In the blow molding method according to this embodiment, the step of adjusting the temperature of the preform may include a step of cooling the preform, but may not include a step of heating the preform.

[0014] The method for filling contents according to this embodiment comprises the steps of obtaining a container by the blow molding method according to this embodiment, and filling the container with contents. [Effects of the Invention]

[0015] According to this disclosure, it is possible to reduce the environmental impact of the blow molding system while maintaining a high level of sterilization effect on the container. [Brief explanation of the drawing]

[0016] [Figure 1] Figure 1 is a schematic plan view showing a blow molding system and a content filling system according to the first embodiment. [Figure 2] Figure 2 is a flow chart showing the blow molding method and content filling method according to the first embodiment. [Figure 3] Figure 3 is a graph showing the change in surface temperature of the preform and container from the injection molding section to the first sterilization section in the first embodiment. [Figure 4] Figure 4 is a schematic plan view showing a blow molding system and a content filling system according to the second embodiment. [Figure 5] Figure 5 is a flow chart showing the blow molding method and content filling method according to the second embodiment. [Figure 6]FIG. 6 is a graph showing changes in the surface temperature of the preform and the container from the injection molding section to the first sterilization section in the second embodiment.

Mode for Carrying Out the Invention

[0017] (First Embodiment) Hereinafter, the first embodiment will be described with reference to the drawings. FIGS. 1 to 3 are diagrams showing the first embodiment.

[0018] (Blow Molding System and Contents Filling System) First, the blow molding system and the contents filling system according to the present embodiment will be described with reference to FIG. 1. Hereinafter, the case where the contents filling system is a sterile filling system will be described as an example.

[0019] The contents filling system 30 shown in FIG. 1 is a system for filling a container 52 with contents such as a beverage. The contents filling system 30 includes a blow molding system 10 and a filling device 20. The blow molding system 10 produces the container 52 by blow molding the preform 51. The blow molding system 10 includes an injection molding section 11, a temperature adjustment section 12, a blow molding section 16, a first sterilization section 17, and an air rinsing section 18. The filling device 20 fills the container 52 with the contents. In the present embodiment, a state in which at least a part of the surface temperature of the preform 51 and the container 52 is maintained at 40° C. or higher, preferably 50° C. or higher, from the injection molding section 11 to the first sterilization section 17. In this specification, the "surface temperature" of the preform 51 and the container 52 refers to the temperature measured at one point on the outer surface located at the center in the longitudinal direction of the preform 51 and the container 52. This measurement position may be located at the body portion of the preform 51 and the body portion of the container 52.

[0020] The injection molding section 11 produces a preform 51 by injection molding. The temperature adjustment section 12 adjusts the temperature of the preform 51 produced by the injection molding section 11. The blow molding section 16 produces a container 52 by blow molding the preform 51 whose temperature has been adjusted by the temperature adjustment section 12. The first sterilization section 17 sterilizes the container 52 produced by the blow molding section 16. In the first sterilization section 17, the container 52 is sterilized while the heat applied in the injection molding section 11 remains.

[0021] The container 52 is produced by biaxially stretch blow molding the preform 51 in the blow molding section 16. The preform 51 is produced by injection molding a synthetic resin material in the injection molding section 11. As the material for the container 52 and the preform 51, it is preferable to use a thermoplastic resin, particularly PE (polyethylene), PP (polypropylene), PET (polyethylene terephthalate), or PEN (polyethylene naphthalate). In the present embodiment, the case of using a synthetic resin bottle as the container 52 will be described as an example.

[0022] As shown in FIG. 1, the content filling system 30 includes, as described above, the blow molding system 10 and the filling device 20. The blow molding system 10 includes an injection molding section 11, a temperature adjustment section 12, a blow molding section 16, a first sterilization section 17, and an air rinsing section 18. These injection molding section 11, temperature adjustment section 12, blow molding section 16, first sterilization section 17, and air rinsing section 18 are arranged in this order from the upstream side to the downstream side along the conveyance direction of the preform 51 or the container 52. In this specification, "upstream" and "downstream" refer to positions in the conveyance direction of the preform 51 or the container 52.

[0023] The contents filling system 30 includes a control unit 40 that controls the entire blow molding system 10. The contents filling system 30 further includes a capping device (capper, crimping and sealing machine) 21 and a product bottle discharge unit 22. These blow molding system 10, filling device 20, capping device 21, and product bottle discharge unit 22 are arranged in this order from upstream to downstream along the transport direction of the container 52. The contents filling system 30 is also provided with a plurality of transport wheels 23 for transporting the container 52 between each device. Here, we will first describe the blow molding system 10.

[0024] The blow molding system 10 is configured to receive resin pellets from the outside and to produce sterilized containers 52. The blow molding system 10 is also configured to transport the molded containers 52 toward the filling device 20. This allows the contents filling system 30 to continuously perform the processes from supplying resin pellets to molding and sterilizing the preforms 51 and containers 52, and finally filling and sealing the containers 52 with their contents. In this case, smaller volume resin pellets, rather than larger volume containers 52, are fed into the contents filling system 30 from the outside. This reduces transportation costs.

[0025] As described above, the blow molding system 10 includes an injection molding unit 11, a temperature control unit 12, a blow molding unit 16, and a first sterilization unit 17. The blow molding system 10 further includes a preform transport unit 37 for transporting the preform 51, a bottle transport unit 38 for transporting the molded containers 52, and an air rinsing unit 18 for air rinsing the sterilized containers 52.

[0026] The injection molding unit 11 is located at the upstream end of the blow molding system 10. The injection molding unit 11 produces a preform 51 by injection molding. The injection molding unit 11 may also be an injection molding machine. The injection molding unit 11 has a fixed frame 31, an injection device 32, and a clamping device 33. The injection device 32 and the clamping device 33 are mounted on the frame 31. The injection device 32 has a hopper 34 and a nozzle 35. Resin pellets are fed from the hopper 34, then melted and mixed, and injected from the nozzle 35. The resin injected from the nozzle 35 is filled into an injection mold 36. The injection mold 36 is attached to the clamping device 33. The injection mold 36 has a cavity corresponding to the shape of the preform 51. The clamping device 33 may have, for example, a fixed plate, a movable plate, and a pressure plate (not shown). The injected resin is formed into the shape of the preform 51 within the injection mold 36. After being held under pressure and cooled as necessary, the preform 51 is removed by opening the injection mold 36.

[0027] The temperature control unit 12 is located downstream of the injection molding unit 11. The temperature control unit 12 has a cooling unit 13 and a heating unit 15. A second sterilization unit 14 is provided between the cooling unit 13 and the heating unit 15.

[0028] The cooling unit 13 cools the preform 51. In the cooling unit 13, a cooling medium, such as air, is blown onto the preform 51 from a cooling nozzle. This lowers the temperature of the preform 51, which has been heated by the heat applied during injection molding in the injection molding unit 11. When using air as the cooling medium, it is preferable to use sterile air that has passed through a sterilization filter. Alternatively, this air may be reused high-pressure air that has been used in the blow molding unit 16, which will be described later.

[0029] The second sterilization unit 14 is located downstream of the cooling unit 13. The second sterilization unit 14 sterilizes the preform 51. In the second sterilization unit 14, for example, a disinfectant gas or mist is sprayed onto the preform 51, thereby sterilizing the preform 51. The disinfectant may be an aqueous hydrogen peroxide solution. The second sterilization unit 14 may also perform preliminary sterilization of the preform 51.

[0030] As a disinfectant for sterilizing Preform 51, any disinfectant that has the property of inactivating microorganisms is acceptable. For example, in addition to hydrogen peroxide, peracetic acid, acetic acid, pernitrate, nitric acid, chlorine-based agents, sodium hydroxide, potassium hydroxide, alcohols such as ethyl alcohol and isopropyl alcohol, chlorine dioxide, ozonated water, acidic water, and surfactants may be used individually or in combination of two or more of these.

[0031] In this way, by pre-sterilizing the preform 51 in the second sterilization unit 14, the amount of bacteria adhering to the container 52 made from the preform 51 can be reduced. Therefore, the amount of disinfectant used in the first sterilization unit 17 to sterilize the container 52 can be reduced, and the sterilization time can be shortened. Generally, the amount of disinfectant used to sterilize the small volume preform 51 tends to be less than the amount of disinfectant used to sterilize the container 52. Therefore, by sterilizing the preform 51 in the second sterilization unit 14, the overall amount of disinfectant used can be reduced.

[0032] Furthermore, the amount of disinfectant used in the first sterilization unit 17 can be reduced, and the sterilization time can be shortened. As a result, the first sterilization unit 17 can be made smaller. In addition, since the sterilization time for sterilizing the container 52 can be shortened, the heat load on the container 52 can be reduced. As a result, even if the container 52 is lightweight or made of recycled PET, deformation of the container 52 due to the heat of the disinfectant can be suppressed.

[0033] Furthermore, sterilizing the preform 51 reduces the amount of bacteria adhering to the container 52. For this reason, the sterilization conditions in the first sterilization unit 17 may be weakened. Generally, in order to improve the sterilization effect in the first sterilization unit 17, the blow molding unit 16 heats the body of the container 52 by supplying hot water from a mold temperature controller (not shown) to the blow molding die. This improves the sterilization effect in the first sterilization unit 17 and reduces the shrinkage of the container 52 in the first sterilization unit 17. Moreover, in this embodiment, as described above, sterilizing the preform 51 in the second sterilization unit 14 reduces the amount of bacteria adhering to the container 52. For this reason, the blow molding unit 16 may mold the container 52 without adjusting its temperature with hot water. In other words, the blow molding unit 16 does not need to supply hot water to the blow molding die, which was previously supplied to improve the sterilization effect. As a result, the amount of carbon dioxide emitted by the contents filling system 30 can be reduced. Furthermore, since it is not necessary to supply hot water to the blow molding die, the blow molding section 16 can be simplified. Also, because the blow molding section 16 can be simplified, the amount of heat applied to the container 52 can be reduced. For this reason, even when the aforementioned hot water is not supplied to the blow molding die, the shrinkage of the container 52 in the first sterilization section 17 can be reduced. In addition, by not heating the body of the container 52 with the mold temperature controller, the amount of hydrogen peroxide adhering in the first sterilization section 17 can be improved.

[0034] Furthermore, this type of sterilization treatment may be performed in multiple locations. Additionally, instead of using disinfectants, bacteria may be inactivated by ultraviolet irradiation or electron beam irradiation during the sterilization process.

[0035] Furthermore, a preform air rinsing section (not shown) may be provided downstream of the second sterilization section 14. In the preform air rinsing section, the preform 51 to which the disinfectant has been sprayed may be dried using hot air. In this case, foreign matter can be effectively removed from within the preform 51.

[0036] The heating unit 15 reheats the preform 51, which has been cooled in the cooling unit 13, to the blow molding temperature. The heating unit 15 receives the sterilized preform 51 from the second sterilization unit 14 and heats the preform 51 while transporting it. The heating unit 15 is equipped with a heater 39 for heating the preform 51. This heater 39 may be, for example, an infrared heater. This heater 39 heats the preform 51 to, for example, 90°C to 130°C. The temperature of the opening of the preform 51 may be kept below 70°C to prevent deformation, etc. The heating unit 15 may also use hot air for heating. If hot air is used, the disinfectant gas used in the second sterilization unit 14 may be added to the hot air to heat and sterilize the preform 51 simultaneously.

[0037] In this embodiment, the cooling unit 13, the second sterilization unit 14, and the heating unit 15 are each provided on different wheels. However, this is not limited to this configuration, and some or all of the cooling unit 13, the second sterilization unit 14, and the heating unit 15 may be provided on the same wheel. Alternatively, the preform 51 may be transported by a transport device that transports the preform 51 along a straight or curved line instead of a wheel. In this case, some or all of the cooling unit 13, the second sterilization unit 14, and the heating unit 15 may be provided along the transport device. As for the method of transporting the preform 51, the preform 51 may be inserted into a mandrel and transported. Alternatively, the preform 51 may be transported by alternately gripping the upper and lower parts of the support ring of the preform 51 with grippers. That is, a first gripper that grips the upper part of the support ring of the preform 51 and a second gripper that grips the lower part of the support ring may be arranged alternately, and the preform 51 may be transported by the first and second grippers alternately gripping the support ring. This prevents interference between adjacent grippers. Note that other methods may also be used.

[0038] The blow molding unit 16 blow-moldes the preform 51 heated in the heating unit 15. The blow molding unit 16 includes a blow molding die (not shown). By blow-molding the preform 51 using this blow molding die, a container 52 is formed. The formed container 52 is then transported downstream by the bottle transport unit 38. A camera may be installed in the bottle transport unit 38 to inspect the top surface and mouth of the container 52, which affect the airtightness of the container 52. Visual inspection of the support ring, body and / or bottom of the container 52 may also be performed. The surface temperature of the container 52, which affects the sterilization effect by the first sterilization unit 17, may be measured using a non-contact infrared camera.

[0039] The first sterilization unit 17 is a device that sterilizes the container 52 by spraying a disinfectant onto the container 52. This sterilizes the container 52 with the disinfectant before it is filled with contents. For example, an aqueous hydrogen peroxide solution is used as the disinfectant. In the first sterilization unit 17, a gas or mist of the aqueous hydrogen peroxide solution is generated and sprayed onto the inner and outer surfaces of the container 52. In this way, the container 52 is sterilized with the gas or mist of the aqueous hydrogen peroxide solution, so that the inner and outer surfaces of the container 52 are sterilized evenly.

[0040] As a disinfectant for sterilizing container 52, any disinfectant that has the property of inactivating microorganisms is acceptable. For example, in addition to hydrogen peroxide, peracetic acid, acetic acid, pernitrate, nitric acid, chlorine-based agents, sodium hydroxide, potassium hydroxide, alcohols such as ethyl alcohol and isopropyl alcohol, chlorine dioxide, ozonated water, acidic water, and surfactants may be used individually or in combination of two or more of these. Alternatively, in the sterilization process, bacteria may be inactivated by ultraviolet irradiation or electron beam irradiation without using a disinfectant.

[0041] The air rinsing unit 18 is a device that supplies sterile heated air or room temperature air to the container 52. In the air rinsing unit 18, foreign matter, hydrogen peroxide, etc. are removed from inside the container 52 while activating the hydrogen peroxide contained in the disinfectant sterilized in the first sterilization unit 17. At this time, it is preferable that sterile air is supplied to the container 52 with the opening of the container 52 facing downwards. This allows for effective removal of foreign matter from inside the container 52. As a result, the step of washing the container 52 with sterile water can be omitted, and the amount of carbon dioxide emitted by the contents filling system 30 can be reduced. If necessary, a low-concentration hydrogen peroxide condensation mist may be mixed with sterilized air at room temperature to gasify the hydrogen peroxide and supply it to the container 52.

[0042] The filling device 20 is a device that fills containers 52 with the contents of a beverage or the like. In other words, the filling device 20 fills the containers 52 with pre-sterilized contents from the opening of the containers 52. In this way, the filling device 20 fills empty containers 52 with contents. In this filling device 20, multiple containers 52 are rotated and conveyed while the contents are filled into the inside of the containers 52.

[0043] The capping device 21 is a device that seals a container 52 by attaching a pre-sterilized cap 53 to the container 52. In the capping device 21, the container 52 filled with contents is closed by the cap 53, sealing the container 52 so that outside air and microorganisms do not enter the container 52. In the capping device 21, multiple containers 52 filled with contents are rotated (revolved) as the cap 53 is attached to their openings. By attaching the cap 53 to the container 52 in this way, a product bottle 54 is obtained.

[0044] The product bottle discharge unit 22 continuously discharges product bottles 54, which have been fitted with caps 53 by the cap attachment device 21, toward the outside of the contents filling system 30.

[0045] The contents filling system 30 also includes an injection molding chamber 61, a preform sterilization chamber 62, a blow molding chamber 63, a disinfectant blocking chamber 68, a disinfectant spraying chamber 64, an air rinse chamber 65, a filling chamber 66, and an outlet chamber 67. The injection molding chamber 61, preform sterilization chamber 62, blow molding chamber 63, disinfectant blocking chamber 68, disinfectant spraying chamber 64, air rinse chamber 65, filling chamber 66, and outlet chamber 67 are arranged in this order from upstream to downstream along the transport direction of the preform 51 and the container 52.

[0046] Each chamber 61 to 68 is separated by a partition wall. The partition wall prevents disinfectants and the like from flowing in unintended directions between the chambers 61 to 68 and stabilizes the pressure inside each chamber 61 to 68. A gap is formed in each partition wall that is large enough for a preform 51 or container 52 to pass through. This gap is formed to a minimum size, for example, about the size of one preform 51 or container 52, so as not to change the pressure inside each chamber 61 to 68. A shutter may also be provided in the partition wall to close the aforementioned gap. This shutter may be configured to open and close automatically, for example, by a signal from the control unit 40. A pressure gauge (not shown) may be installed inside each chamber 61 to 68 to measure the pressure inside each chamber 61 to 68.

[0047] The injection molding chamber 61 houses the injection molding unit 11. The preform sterilization chamber 62 houses the cooling unit 13 and the second sterilization unit 14. The blow molding chamber 63 houses the heating unit 15 and the blow molding unit 16. The disinfectant spray chamber 64 houses the first sterilization unit 17. The air rinsing chamber 65 houses the air rinsing unit 18. The filling chamber 66 houses the filling device 20 and the capping device 21. The outlet chamber 67 houses the product bottle discharge unit 22. The disinfectant blocking chamber 68 is a chamber that exhausts disinfectant to prevent it from flowing from the first sterilization unit 17 to the blow molding unit 16 side due to the positive pressure atmosphere inside the filling chamber 66.

[0048] As described above, the contents filling system 30 includes a control unit 40 that controls the blow molding system 10. This control unit 40 is electrically connected to the blow molding system 10 and controls the injection molding unit 11, temperature adjustment unit 12, blow molding unit 16, and first sterilization unit 17 of the blow molding system 10. The control unit 40 may also control the air rinsing unit 18, filling device 20, cap attachment device 21, and product bottle discharge unit 22, etc. In this embodiment, the injection molding unit 11, temperature adjustment unit 12, blow molding unit 16, and first sterilization unit 17 of the blow molding system 10 are controlled by the same control unit 40. This allows for efficient control of the injection molding unit 11, temperature adjustment unit 12, blow molding unit 16, and first sterilization unit 17. Furthermore, for example, the transport speed of the preform 51 and container 52 in the injection molding unit 11, temperature adjustment unit 12, blow molding unit 16, and first sterilization unit 17 can be easily adjusted.

[0049] Such a contents filling system 30 may consist of, for example, an aseptic filling system. In this case, the inside of each chamber 61 to 68 is kept sterile. A chamber (not shown) connecting a sterile zone and a non-sterile zone may be provided downstream of the outlet chamber 67.

[0050] (Blow molding method and content filling method) Next, a blow molding method using the blow molding system 10 (Figure 1) according to this embodiment, and a content filling method using the content filling system 30 (Figure 1) will be explained with reference to Figure 2.

[0051] First, a preform 51 is manufactured by injection molding in the injection molding section 11 of the blow molding system 10 (injection molding process, step S1 in Figure 2). During this time, resin pellets are first fed into the hopper 34 of the injection molding section 11. The resin pellets are melted and kneaded at a temperature of 200°C to 250°C and then injected from the nozzle 35. The resin injected from the nozzle 35 is filled into the injection molding die 36. The resin is shaped into the form of the preform 51 within the injection molding die 36. After being held under pressure and cooled as necessary, the preform 51 is removed by opening the injection molding die 36. The surface temperature T1 of the preform 51 removed from the injection molding section 11 may be between 100°C and 150°C.

[0052] Next, the preform 51 is supplied to the temperature control unit 12 via the preform transport unit 37. In the temperature control unit 12, the temperature of the preform 51 is adjusted (temperature adjustment step). In this embodiment, the temperature adjustment step includes a preform cooling step and a preform heating step, which will be described later.

[0053] During this time, the preform 51 is first cooled in the cooling unit 13 (preform cooling process, step S2 in Figure 2). In the cooling unit 13, a cooling medium such as sterile air is blown onto the preform 51 from a cooling nozzle, and the preform 51 is forcibly cooled. The surface temperature T2 of the preform 51 cooled in the cooling unit 13 is lower than the surface temperature T1 mentioned above. Specifically, the surface temperature T2 of the preform 51 after cooling in the cooling unit 13 may be between 50°C and 100°C. By keeping the surface temperature T2 of the preform 51 below 100°C in this way, when a disinfectant such as hydrogen peroxide is blown onto the preform 51 in the second sterilization unit 14, the disinfectant gas condenses on the surface of the preform 51. This allows the preform 51 to be sterilized with high disinfecting power using only a small amount of disinfectant. The cooling air may also contain disinfectant gas (e.g., hydrogen peroxide) or mist. When using hydrogen peroxide, the gas concentration can be 0.1 mg / L to 300 mg / L, and more preferably 1 mg / L to 10 mg / L.

[0054] Next, the preform 51 cooled in the cooling section 13 is sent to the second sterilization section 14 (preform sterilization process, step S3 in Figure 2). At this time, in the second sterilization section 14, the preform 51 is sterilized by being sprayed with a gas or mist of a disinfectant such as hydrogen peroxide. At this time, it is preferable that both the inner and outer surfaces of the preform 51 are sterilized. The gas concentration of hydrogen peroxide may be 0.1 mg / L to 300 mg / L, and more preferably 1 mg / L to 10 mg / L. The surface temperature T3 of the preform 51 in the second sterilization section 14 may be the same as or less than the surface temperature T2 described above. Specifically, the surface temperature T3 of the preform 51 in the second sterilization section 14 may be 50°C or more and 100°C or less.

[0055] Next, the preform 51 sterilized in the second sterilization section 14 is sent to the heating section 15 and heated to a temperature suitable for blow molding by the heater 39 (preform heating process, step S4 in Figure 2). The surface temperature T4 of the preform 51 heated in the heating section 15 is higher than the surface temperature T3 mentioned above. Specifically, the surface temperature T4 of the preform 51 may be between 90°C and 130°C. Next, the preform 51 heated by the heating section 15 is sent to the blow molding section 16.

[0056] In this embodiment, the preform 51 manufactured in the injection molding section 11 is sent to the blow molding section 16 while its surface temperature is below 40°C, and in particular, does not drop to room temperature (15°C to 25°C). In other words, it is transported consistently from the injection molding section 11 to the blow molding section 16 while retaining the heat from injection molding. This eliminates the need for transporting the preform 51 and the aging process of the preform 51. As a result, energy required during the manufacture of the container 52 can be reduced, and carbon dioxide emissions can be lowered. Furthermore, the space required for storing the preform 51 can be reduced.

[0057] Next, the preform 51 sent to the blow molding section 16 is blow-molded using a blow molding die (not shown) to produce a container 52 (blow molding process, step S5 in Figure 2). The surface temperature T5 of the container 52 after blow molding in the blow molding section 16 is lower than the surface temperature T4 mentioned above. Specifically, the surface temperature T5 of the container 52 may be between 40°C and 100°C. The blow-molded container 52 is then sent to the first sterilization section 17 via the bottle transport section 38.

[0058] Next, in the first sterilization unit 17, the container 52 is sterilized using a disinfectant such as an aqueous hydrogen peroxide solution (container sterilization process, step S6 in Figure 2). At this time, the disinfectant may be a gas or mist obtained by vaporizing an aqueous hydrogen peroxide solution above its boiling point. The gas or mist of the aqueous hydrogen peroxide solution adheres to the inner and outer surfaces of the container 52, sterilizing the inner and outer surfaces of the container 52. The surface temperature T6 of the container 52 in the first sterilization unit 17 may be equal to or less than the surface temperature T5 described above. Specifically, the surface temperature T6 of the preform 51 in the first sterilization unit 17 may be between 40°C and 100°C. By setting the surface temperature T6 of the preform 51 to 100°C or less in this way, when a disinfectant such as hydrogen peroxide is sprayed onto the container 52 in the first sterilization unit 17, the disinfectant gas condenses on the surface of the container 52. As a result, the container 52 can be sterilized with high disinfecting power using only a small amount of disinfectant.

[0059] Thus, after the preform 51 is manufactured by injection molding in the injection molding unit 11, the surface temperature of the preform 51 and the container 52 is maintained at 40°C or higher until the container 52 is sterilized in the first sterilization unit 17. In other words, the container 52 is sterilized in the first sterilization unit 17 while the heat from injection molding is still present. This allows the heat from injection molding to be used to sterilize the container 52 with high sterilization power in the first sterilization unit 17. Furthermore, by directly transporting the preform 51 and the container 52 from the injection molding unit 11 to the first sterilization unit 17, the number of bacteria adhering to the preform 51 and the container 52 can be reduced to as close to zero as possible. Sterile air may be supplied to the chambers 62-68, where the preform 51 or container 52 comes into contact with the outside air, using a HEPA filter (High Efficiency Particulate Air Filter), and the inside of the chambers 62-68 may be kept under positive pressure. This makes it possible to further enhance the hygiene of the container 52. Furthermore, chambers 62-68 may be sterilized with disinfectants such as hydrogen peroxide or peracetic acid before production of product bottles 54.

[0060] Figure 3 is a graph showing the change in surface temperature of the preform 51 and container 52 from the injection molding section 11 to the first sterilization section 17 in this embodiment. As shown in Figure 3, the surface temperature T1 of the preform 51 immediately after injection molding in the injection molding section 11 is cooled in the cooling section 13 and decreases to T2. In the second sterilization section 14, the surface temperature of the preform 51 is T3, and the preform 51 is sterilized in this state. After that, the surface temperature of the preform 51 is heated in the heating section 15 and rises to T4. In the blow molding section 16, the container 52 is manufactured by blow molding the preform 51. After blow molding, the surface temperature of the container 52 decreases to T5. In the first sterilization section 17, the surface temperature of the preform 51 is T6, and the preform 51 is sterilized in this state. Note that the relative magnitudes of T6 and T3 are not considered. As shown in Figure 3, the surface temperature of the preform 51 and the container 52 never falls below 40°C from the injection molding section 11 to the first sterilization section 17.

[0061] Next, the container 52 is sent from the first sterilization unit 17 to the air rinsing unit 18. In the air rinsing unit 18, the container 52 is air-rinsed by supplying sterile heated air or room temperature air (air rinsing process, step S7 in Figure 2). This activates the hydrogen peroxide and removes foreign matter and hydrogen peroxide from the container 52. In the air rinsing process, if necessary, a low-concentration hydrogen peroxide condensation mist may be mixed with the sterile heated air or sterilized room temperature air. In this case, the hydrogen peroxide is gasified by the sterile air. Then, in the air rinsing process, the gasified hydrogen peroxide may be supplied to the container 52.

[0062] Next, the container 52 is transported from the blow molding system 10 to the filling device 20. In the filling device 20, the contents such as a beverage are filled into the container 52 (filling process, step S8 in Figure 2). In the filling device 20, the container 52 rotates (revolves) as the contents are filled into the container 52 from its opening.

[0063] Next, the container 52 filled with contents is transported to the capping device 21 by the transport wheel 23. In this capping device 21, a sterilized cap 53 is attached to the mouth of the container 52 that has been transported from the filling device 20 (capping process, step S9 in Figure 2). This closes the container 52 and produces a product bottle 54.

[0064] Subsequently, the product bottle 54 is transported from the cap-attaching device 21 to the product bottle discharge section 22 and discharged to the outside of the contents filling system 30 (discharge process, step S10 in Figure 2). The product bottle 54 is then transported to a packaging line (not shown) and packaged.

[0065] Furthermore, the above injection molding process, preform cooling process, preform sterilization process, preform heating process, blow molding process, container sterilization process, air rinsing process, filling process, capping process, and unloading process may be carried out in a sterile atmosphere, i.e., a sterile environment, within chambers 61 to 68. In this case, chambers 61 to 68 may be sterilized in advance by spraying hydrogen peroxide or peracetic acid, or by spraying alkaline detergent or hot water. Only the injection molding chamber 61 in which the above injection molding process is carried out may be a non-sterile area. Alternatively, the injection molding chamber 61, preform sterilization chamber 62, and blow molding chamber 63 may all be a non-sterile area.

[0066] Furthermore, the production (conveying) speed of the preform 51 and container 52 in the contents filling system 30 is preferably 100 bpm or more and 1000 bpm or less. Here, bpm (bottles per minute) refers to the conveying speed of the container 52 per minute.

[0067] As described above, according to this embodiment, the surface temperature of the preform 51 and the container 52 is maintained at 40°C or higher from the injection molding section 11 to the first sterilization section 17. That is, the preform 51 and the container 52 are transported to the first sterilization section 17 while the heat from injection molding in the injection molding section 11 remains, and sterilization is performed. In this way, the surface temperature of the container 52 is 40°C or higher during sterilization in the first sterilization section 17, thereby enhancing the sterilization effect of the container 52. Furthermore, compared to the case where the temperature of the preform 51 or the container 52 returns to room temperature, the energy required to raise the temperature of the preform 51 in the blow molding section 16 or the temperature of the container 52 in the first sterilization section 17 can be reduced. This reduces the amount of carbon dioxide emitted when manufacturing the product bottle 54. In addition, since the heating area required to raise the preform 51 to the blow molding temperature can be narrowed, the installation space of the blow molding system 10 can be reduced.

[0068] Furthermore, according to this embodiment, the temperature control unit 12 includes a cooling unit 13 for cooling the preform 51 and a heating unit 15 for heating the preform 51 that has been cooled by the cooling unit 13. A second sterilization unit 14 for sterilizing the preform 51 is provided between the cooling unit 13 and the heating unit 15. By sterilizing the preform 51 in advance with the second sterilization unit 14 in this way, the amount of bacteria adhering to the container 52 can be reduced. As a result, the amount of disinfectant used in the first sterilization unit 17 for sterilizing the container 52 can be reduced, and the sterilization time can be shortened. As a result, the amount of carbon dioxide emitted when manufacturing the product bottle 54 can be reduced.

[0069] Furthermore, according to this embodiment, the injection molding unit 11, temperature control unit 12, blow molding unit 16, and first sterilization unit 17 are controlled by the same control unit 40. In other words, the injection molding unit 11 to the first sterilization unit 17 constitute a single, integrated system. This reduces the installation space for the blow molding system 10 and the space required for storing and housing the injection-molded preforms 51. In addition, since the injection-molded preforms 51 are not transported to the blow molding unit 16 by vehicle or the like, the amount of carbon dioxide emitted during the transportation of the preforms 51 can be reduced.

[0070] (Second Embodiment) Next, a second embodiment will be described with reference to Figures 4 to 6. Figures 4 to 6 show the second embodiment. The second embodiment shown in Figures 4 to 6 mainly differs in the configuration of the temperature control unit 12, while other configurations are substantially the same as those of the first embodiment described above. In Figures 4 to 6, the same reference numerals are used for parts that are the same as those in the first embodiment shown in Figures 1 to 3, and detailed descriptions are omitted.

[0071] (Blow molding system and content filling system) First, the blow molding system and the content filling system according to this embodiment will be explained with reference to Figure 4.

[0072] As shown in Figure 4, the contents filling system 30 according to this embodiment comprises a blow molding system 10 and a filling device 20. The blow molding system 10 produces a container 52 by blow molding a preform 51. The filling device 20 fills the container 52 with contents.

[0073] The blow molding system 10 according to this embodiment comprises an injection molding unit 11, a temperature control unit 12, a blow molding unit 16, a first sterilization unit 17, and an air rinsing unit 18. The temperature control unit 12 has a cooling unit 13. In this case, unlike the blow molding system 10 according to the first embodiment, the temperature control unit 12 does not have a heating unit 15 for heating the preform 51. Also, in this embodiment, the blow molding system 10 does not have a second sterilization unit 14 for sterilizing the preform 51. However, it is not limited to this, and a second sterilization unit 14 for sterilizing the preform 51 may be provided between the injection molding unit 11 and the blow molding unit 16.

[0074] The cooling unit 13 cools the preform 51 to the blow molding temperature. The cooling unit 13 receives the preform 51 from the injection molding unit 11 and cools the preform 51 while transporting it. In the cooling unit 13, a cooling medium such as air is blown onto the preform 51 from a cooling nozzle. This lowers the temperature of the preform 51, which was heated by the heat applied during injection molding in the injection molding unit 11. The cooling unit 13 lowers the surface temperature of the preform 51 to, for example, between 90°C and 130°C.

[0075] In this embodiment, the cooling unit 13 is provided on the wheel. Alternatively, the preform 51 may be transported by a transport device that transports the preform 51 along a straight or curved line instead of the wheel. In this case, the cooling unit 13 may be provided along the transport device.

[0076] The blow molding section 16 blow-moldes the preform 51, which has been temperature-controlled to the blow molding temperature in the cooling section 13. By blow-molding the preform 51 in the blow molding section 16, the container 52 is formed.

[0077] In this embodiment, the preform sterilization chamber 62 is not provided. The cooling unit 13 may be located inside the blow molding chamber 63.

[0078] Furthermore, in the blow molding section 16, a disinfectant gas (e.g., hydrogen peroxide) may be added to the air blown out from the stretching rod during blow molding. When hydrogen peroxide is used as the disinfectant, the gas concentration may be 0.1 mg / L to 300 mg / L, and more preferably 1 mg / L to 10 mg / L. This allows the preform 51 to be sterilized during blow molding. Also, the sterilization and molding of the container 52 can be carried out simultaneously. Such sterilization in the blow molding section 16 may be performed as an alternative to the sterilization of the preform 51 in the second sterilization section 14. Alternatively, it may be performed together with the sterilization of the preform 51 in the second sterilization section 14.

[0079] In addition, the elements constituting the blow molding system 10 and the contents filling system 30 are substantially the same as those in the first embodiment.

[0080] (Blow molding method and content filling method) Next, a blow molding method using the blow molding system 10 (Figure 4) according to this embodiment, and a content filling method using the content filling system 30 (Figure 4) will be explained with reference to Figure 5.

[0081] First, as in the first embodiment, a preform 51 is manufactured by injection molding in the injection molding section 11 of the blow molding system 10 (injection molding process, step S1 in Figure 5). The surface temperature T1 of the preform 51 removed from the injection molding section 11 may be between 100°C and 150°C.

[0082] Next, the preform 51 is supplied to the temperature control unit 12 via the preform transport unit 37. In the temperature control unit 12, the temperature of the preform 51 is adjusted (temperature adjustment step). In this embodiment, the temperature adjustment step includes a preform cooling step, which will be described later.

[0083] During this time, the preform 51 is cooled in the cooling section 13 (preform cooling process, step S2 in Figure 5). In the cooling section 13, a cooling medium such as air is blown onto the preform 51 from a cooling nozzle, and the preform 51 is forcibly cooled. In the cooling section 13, the preform 51 is cooled to a temperature suitable for blow molding. The surface temperature T7 of the preform 51 cooled in the cooling section 13 is lower than the surface temperature T1 described above. Specifically, the surface temperature T7 of the preform 51 after cooling in the cooling section 13 may be between 90°C and 130°C. Next, the preform 51 cooled in the cooling section 13 is sent to the blow molding section 16.

[0084] Next, similar to the first embodiment, the container 52 is blow-molded by blow molding the preform 51 sent to the blow molding section 16 using a blow molding die (not shown) (blow molding process, step S5 in Figure 5). The surface temperature T5 of the container 52 blow-molded in the blow molding section 16 is lower than the surface temperature T7 described above. Specifically, the surface temperature T5 of the container 52 may be between 40°C and 100°C.

[0085] Next, similar to the first embodiment, the container 52 is sterilized in the first sterilization unit 17 using a disinfectant such as an aqueous hydrogen peroxide solution (container sterilization step, step S6 in Figure 5). The surface temperature T6 of the container 52 in the first sterilization unit 17 may be equal to or less than the surface temperature T5 described above. Specifically, the surface temperature T6 of the preform 51 in the first sterilization unit 17 may be between 40°C and 100°C. By setting the surface temperature T6 of the preform 51 to 100°C or less, when a disinfectant such as hydrogen peroxide is sprayed onto the container 52 in the first sterilization unit 17, the disinfectant gas condenses on the surface of the container 52. As a result, the container 52 can be sterilized with high disinfecting power using only a small amount of disinfectant.

[0086] Thus, after the preform 51 is manufactured by injection molding in the injection molding unit 11, the surface temperature of the preform 51 and the container 52 is maintained at 40°C or higher until the container 52 is sterilized in the first sterilization unit 17. In other words, the container 52 is sterilized in the first sterilization unit 17 while the heat from injection molding is still present. This allows the heat from injection molding to be used to sterilize the container 52 with high sterilization power in the first sterilization unit 17. Furthermore, by directly transporting the preform 51 and the container 52 from the injection molding unit 11 to the first sterilization unit 17, the number of bacteria adhering to the preform 51 and the container 52 can be reduced to as close to zero as possible. Sterile air may be supplied to the chambers 63-68, where the preform 51 or container 52 comes into contact with the outside air, using a HEPA filter, and the chambers 63-68 may be kept under positive pressure. This makes it possible to further enhance the hygiene of the container 52. Furthermore, chambers 63-68 may be sterilized with disinfectants such as hydrogen peroxide or peracetic acid before production of product bottles 54.

[0087] Figure 6 is a graph showing the change in surface temperature of the preform 51 and container 52 from the injection molding section 11 to the first sterilization section 17 in this embodiment. As shown in Figure 6, the surface temperature T1 of the preform 51 immediately after injection molding in the injection molding section 11 is cooled in the cooling section 13 and decreases to T7. Subsequently, the container 52 is manufactured by blow molding the preform 51 in the blow molding section 16. The surface temperature of the container 52 after blow molding decreases to T5. In the first sterilization section 17, the surface temperature of the preform 51 is T6, and the preform 51 is sterilized in this state. As shown in Figure 6, the surface temperature of the preform 51 and container 52 never falls below 40°C from the injection molding section 11 to the first sterilization section 17.

[0088] Next, similar to the first embodiment, the container 52 is air-rinsed in the air-rinsing section 18 by supplying sterile heated air or room-temperature air (air-rinsing step, step S7 in Figure 5).

[0089] Next, similar to the first embodiment, the contents such as a beverage are filled into the container 52 in the filling device 20 (filling process, step S8 in Figure 5).

[0090] Next, as in the first embodiment, the capping device 21 attaches a sterilized cap 53 to the mouth of the container 52 that has been transported from the filling device 20 (capping process, step S9 in Figure 5). This closes the container 52 and yields a product bottle 54.

[0091] Subsequently, as in the first embodiment, the product bottle 54 is transported from the cap attachment device 21 to the product bottle discharge unit 22 and discharged to the outside of the contents filling system 30 (discharge process, step S10 in Figure 5).

[0092] As described above, according to this embodiment, the surface temperature of the preform 51 and the container 52 is maintained at 40°C or higher from the injection molding section 11 to the first sterilization section 17. That is, the preform 51 and the container 52 are transported to the first sterilization section 17 while the heat from injection molding in the injection molding section 11 remains, and sterilization is performed. In this way, the surface temperature of the container 52 is 40°C or higher during sterilization in the first sterilization section 17, thereby enhancing the sterilization effect of the container 52. Furthermore, compared to the case where the temperature of the preform 51 or the container 52 returns to room temperature, the energy required to raise the temperature of the container 52 in the first sterilization section 17 can be reduced. This reduces the amount of carbon dioxide emitted when manufacturing the product bottle 54. In addition, since the heating area required to raise the preform 51 to the blow molding temperature can be narrowed, the installation space of the blow molding system 10 can be reduced.

[0093] Furthermore, according to this embodiment, the temperature control unit 12 has a cooling unit 13 for cooling the preform 51, but does not have a heating unit 15 for heating the preform 51. This reduces the energy required to heat the preform 51 to the blow molding temperature. This reduces the amount of carbon dioxide emitted when manufacturing the product bottle 54. In addition, since the installation area of ​​the temperature control unit can be narrowed, the installation space of the blow molding system 10 can be reduced.

[0094] The multiple components disclosed in the above embodiments and variations can be combined as needed. Alternatively, some components may be removed from all the components shown in the above embodiments and variations. [Explanation of symbols]

[0095] 10 Blow molding system 11 Injection molding section 12 Temperature adjustment section 13 Cooling section 14 2nd sterilization section 15 Heating section 16 Blow molding section 17 1st sterilization department 18 Air Rinse Section 20 Filling equipment 21 Cap mounting device 22 Product Bottle Dispensing Section 30 Contents filling system 40 Control Unit 51 Preform 52 Container 53 Cap 54 product bottles

Claims

1. An injection molding section that produces preforms by injection molding, A temperature control unit for adjusting the temperature of the preform manufactured by the injection molding unit, A blow molding unit that produces a container by blow molding the preform whose temperature has been adjusted by the temperature adjustment unit, The system includes a first sterilization unit for sterilizing the container manufactured in the blow molding unit, From the injection molding section to the first sterilization section, the surface temperature of at least a portion of the preform and the container is maintained at 40°C or higher. The temperature control unit has a cooling unit that cools the preform by blowing sterile air onto it. The surface temperature of the preform removed from the injection molding section is between 100°C and 150°C. The surface temperature of the preform after cooling in the cooling section is between 50°C and 100°C. The surface temperature of the container after blow molding in the blow molding section is 40°C to 100°C. A blow molding system in which the surface temperature of the container in the first sterilization section is 40°C or more and 100°C or less.

2. The injection molding unit is housed inside the injection molding chamber. The cooling unit is housed inside the preform sterilization chamber. The blow molding section is housed inside the blow molding chamber. The first sterilization unit is housed inside the disinfectant spray chamber. The inside of the preform sterilization chamber, the blow molding chamber, and the disinfectant spray chamber are kept in a sterile atmosphere. The blow molding system according to claim 1, wherein the insides of the preform sterilization chamber, the blow molding chamber, and the disinfectant spray chamber are under positive pressure.

3. The blow molding system according to claim 1 or 2, wherein in the blow molding section, a disinfectant gas is added to the air blown out from the stretching rod during blow molding.

4. A blow molding system according to any one of claims 1 to 3, A content filling system comprising a filling device for filling the aforementioned container with contents.

5. In the injection molding section, there is a process of manufacturing a preform by injection molding, In the temperature control section, there is a step of adjusting the temperature of the preform, In the blow molding section, a process is performed to manufacture a container by blow molding the temperature-controlled preform, The first sterilization section includes a step of sterilizing the container, After the preform is manufactured by the injection molding process, the surface temperature of the preform and at least a portion of the container is maintained at 40°C or higher until the container is sterilized. The step of adjusting the temperature of the preform is, The cooling section includes a step of cooling the preform by blowing sterile air onto it. The surface temperature of the preform removed from the injection molding section is between 100°C and 150°C. The surface temperature of the preform after cooling in the cooling section is between 50°C and 100°C. The surface temperature of the container after blow molding in the blow molding section is 40°C to 100°C. A blow molding method wherein the surface temperature of the container in the first sterilization section is 40°C or more and 100°C or less.

6. A step of obtaining a container by the blow molding method described in claim 5, A method for filling a container, comprising the step of filling the container with contents.

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