A bottling line and method for aseptically bottling liquid products into bottles.

Abstract

To provide a bottling line and a method for filling a liquid product in a bottle aseptically.SOLUTION: A bottling line 1 comprises a machine block 2 including a blow molding machine 4 for manufacturing bottles 8a and supplying them as a stream of bottles and a clean room housing 3. The blow molding machine comprises: at least one of first and second transportation paths 9a and 10a including one filler 5 or 6 to fill the bottles, respectively; and distribution means 7 for dividing the stream of bottles into the transportation paths in a completely occupied transportation system so that the bottles are continuously filled at all circulation filling positions. The clean room housing encloses the machine block, at least one of the fillers is embodied as a support plate filler including a central star wheel column so as to enable the handling for protecting a material of the bottle and product in low structural effort and space requirement.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD

[0001] The present invention relates to a bottling line for aseptically bottling liquid products, in particular beverages, and a method for aseptically filling liquid products into bottles.

[0002] Liquid products such as beverages are increasingly being bottled on bottling lines, in which the individual production units, processing units and inspection units are exclusively connected to one another together with circulating transport bags and / or holders by means of transfer starwheels or similar conveying means. A combination of machines arranged in this way within a block with regard to conveying is usually referred to as a machine block. Such a machine block is known, for example, from DE 20 2009 019 170.

[0003] In order to optionally enable different containers and / or different products to be processed simultaneously, it is further known from DE 10 2016 110 016 and FR 4 070 970 to divide the container stream directly downstream of the blow molding machine into two conveying paths and feed them to two downstream filling machines. According to FR 4 070 970, the containers are alternately fed to the first and second filling machines by a switching starwheel, and the containers can optionally be filled with the same product in both filling machines. In DE 10 2016 110 016, the transport of the containers in the conveying path is carried out to the respective filling machine using a conveyor belt.

[0004] Apart from the general need for flexibility in the bottling process, there is an increasing demand for improved equipment performance, which means the number of containers that can be bottled per unit of time. It has become clear that not only the bottling process, which cannot be shortened as needed for physical reasons, but also the direct subsequent handling of filled containers is a limitation. It has been found that filled products can spill out if their direction changes as the conveying speed increases. Furthermore, the closing process becomes less safe due to the high rotational speed of the system. In addition, there are problems with the feeding of the closing caps in the corresponding rapid closing operation. Moreover, in passive designs, the clamps that grip the container in the neck region below the support ring, especially the neck clamps, can only withstand the centrifugal force acting on the container to some extent. During bottling in a filling machine, the centrifugal force increases dramatically as the product flowing into the container increases the weight of the container. Here, depending on the bottle contour, filling level, and bottle product, the machine performance reaches 48,000 bottles per hour, which, as experience shows, is the physical maximum.

[0005] Furthermore, due to the extremely high orbital speed, if a mechanical blockage of the bottle occurs in the machine, it can result in significant damage that is very time-consuming and costly to repair.

[0006] Aseptic bottling, with typical equipment capacities of 8,000 to 54,000 bottles per hour, necessitates additional technical effort. For this purpose, bottles are always handled by neck handling during transport. At higher performance ranges, relatively large filling machines are required, designed in a relatively complex and space-consuming manner as so-called carousel fillers with an integrated, annular aseptic area, in which case the aseptic area must be hydraulically sealed, for example, by a liquid barrier during rotation. Similar requirements apply to closure machines.

[0007] As mentioned above, when the machine performance exceeds 36,000 bottles / hour, technical problems related to neck handling become uncontrollable in terms of mechanical wear and readjusted precision. Therefore, it is unavoidable to further stabilize the bottles by equipping them with guide fittings on the bottle body. The guide fittings must be set specifically for the size and shape, which is not possible automatically and is therefore disadvantageous.

[0008] With a machine capacity of up to 36,000 bottles per hour, so-called support plate fillers can also be used as an alternative to carousel fillers when bottles are transported by star wheels during bottling. Corresponding construction principles are known from, for example, EP 0 758 624 A1, EP 1 851 147 B1, EP 1 254 071 B1, and DE 20 2007 017 932 U1. The advantage of the support plate design is that, in contrast, no additional sterile area is required within the filling assembly.

[0009] Therefore, depending on the equipment's performance, different filler designs may be adopted, but in that case, the cleanroom housing, cleaning process, and ventilation / air treatment must be adapted accordingly. This results in a high level of individual construction effort for each bottling line.

[0010] Furthermore, it would be desirable to design the outlet of the closed container to be more compact, because conventional subsequent outlet belts must include a long straight section on the inlet side in order to sufficiently slow down the bottle stream and selectively discharge defective bottles.

[0011] Therefore, there is a need for a bottling line and method for bottled liquid products that can manufacture bottles in a sterile condition, bottle them in a single machine block, and mitigate or completely eliminate at least one of the aforementioned problems.

[0012] It is also desirable to enable the bottling line and method to be operated and controlled in a preferably simple and flexible manner. [Overview of the Initiative]

[0013] This objective is achieved by the bottling line described in claim 1 and the method described in claim 13.

[0014] Therefore, a bottling line helps to aseptically fill liquid products, particularly beverages, into bottles or similar containers. For this purpose, a bottling line includes a mechanical block in which individual manufacturing units, processing units, and / or inspection units are connected in a block-like manner with respect to transport by star-shaped conveying means, such as moving a star wheel, and at least one cleanroom housing surrounding the mechanical block.

[0015] The machine block is, A blow molding machine that manufactures bottles and supplies them as a stream of bottles, A first and second transport path having at least one filling machine each for filling bottles, A distribution unit for dividing the bottle stream into transport paths within a fully occupied transport system, so that bottles can be continuously filled at all circulating filling positions of the filling machine, The filling machine comprises at least one of which is embodied as a support plate filler having a central star wheel column (star wheel column filler).

[0016] Preferably, all filling machines in the bottling line are embodied as support plate fillers.

[0017] By dividing the bottle stream into a transport path, the amount of equipment required for single-track bottle production upstream of the distribution unit can be minimized. At the same time, the transport speed in the transport path can be reduced relative to the single-track bottle stream, thereby allowing the bottling process to be carried out with a relatively small filling machine, requiring less space, and avoiding spillage of the filled product.

[0018] Furthermore, the feeding of the closing caps to the next closing process is more reliable, and the closing process itself is more stable. In addition, the outlet speed on the outlet conveyor can be reduced completely with respect to the transport speed of the single-track stream of bottles. This facilitates the discharge of improperly filled and / or unclosed containers, or containers for inspection purposes in general. Overall, this principle has a positive effect not only on production operations but also on machine installation and commissioning.

[0019] A fully occupied transport system means that bottles can be transported from the blow molding machine to the filling machine without skipping any transport and processing positions. However, individual transport and processing positions can be intentionally skipped, for example, in the event of a failure in one of the filling machines. Intentional skipping of transport and processing positions is possible, for example, by discharging bottles from a single-track stream of bottles or a partial stream of the transport path formed thereby, or, for example, by attaching preforms to the blow molding positions (blow molds) that circulate every second in the blow molding machine.

[0020] Support plate fillers can be designed in series for different performance ranges and can be modularly combined with each other. Suitable performance grades for individual types of support plate fillers are, for example, 8,000, 12,000, 18,000, 24,000, and 36,000 bottles per hour.

[0021] Support plate fillers are also called star wheel column fillers.

[0022] A support plate filler / star wheel column filler in the sense of the present invention includes at least one of the following construction features: The support plate filler has a support plate formed such that the bottom plate of the cleanroom housing surrounds the support plate filler. The support plate filler includes a rotary drive unit formed beneath the support plate / below the bottom plate of the cleanroom housing surrounding the support plate filler. The support plate filler is continuously driven by a rotary drive unit and includes a star wheel column that extends through the bottom plate / support plate. • The filler carousel is mounted on a star wheel column. The filler carousel comprises a clamp support with clamps for receiving bottles, a filling valve support with a filling valve, and a corresponding feeding unit that rotates along the filling valve positioned thereon. • The support plate / bottom plate is further embodied to accommodate the insertion star wheel, the exit star wheel, and / or the star wheel column of the subsequent closing machine.

[0023] In contrast, so-called carousel fillers have a larger diameter and do not readily fit into typical cleanrooms with a rectangular plan view. Therefore, typically, a portion of the carousel filler, which is additionally housed, protrudes from the cleanroom, which is inherently cubic. Additional cleanroom walls are provided inside the carousel filler, radially inside the filling valve, and along the machine axis. In this way, a sterile annular room is provided for the carousel filler in which bottling takes place. Because of this annular room, the innermost filler is not located within the cleanroom area, so the drive unit of the carousel filler is connected directly to its star wheel column and does not penetrate the support plate.

[0024] For a performance exceeding 36,000 bottles per hour, the bottling line includes two support plate fillers connected in parallel. Medium feeding, particularly product feeding, ventilation, and cleaning (CIP) are centrally controlled here, meaning they are combined for both filling machines.

[0025] This allows for a modular bottling line with a uniform filling machine design and slower conveying speeds during bottle filling. Related advantages include, for example, ·Reduce the mechanical load on the constituent components. Even when used to the maximum extent, the neck handling clamp method can meet the required service life of, for example, 1 year. More reliable bottle transfer through neck handling. ·The lower the relative speed, the easier it is to maintain manufacturing tolerances. ·Relatively compact machines shorten processing time in production, thus enabling stock production while not reducing future-proof production concepts. ·Even when used to the maximum extent, the ejection of products during / after cornering can be reliably prevented. The number of assemblies produced can be increased, and the degree of cost efficiency and standardization in both production and production operations can be enhanced. ·Due to the low track speed of the conveying route, the setup time is shortened, the accuracy requirement for installation is reduced, and commissioning is accelerated. ·The product line from the boiler to the filling valve can be designed to be much shorter, which reduces the height of the container and simplifies the ventilation of the filling valve. ·Pressure-bearing components such as filling containers are reduced in size with respect to their performance, which makes it easier to conform to local pressure equipment lines. ·In embodiments with two support plate fillers, these can be used as structural frames for the platform of the bottling line. Then, additional platform substructures can be omitted. ·Since the relative speed of the bottles is correspondingly low, a more reliable and gentle bottle outlet is achieved. ·If one filling machine fails, partial load operation is possible (50% operation)

[0026] Preferably, the blow molding machine and the distribution unit are arranged in a first clean room housing, the first conveying path is arranged in a second clean room housing containing the filling machine, and the second conveying path is arranged in a third clean room housing containing the filling machine. This facilitates partial load operation even with a stopped filling machine.

[0027] The bottling line preferably includes an air treatment unit for a common air supply to the first, second, and third cleanroom housings. This facilitates the ventilation system. In this way, complete air treatment can be combined into one single-function unit, thus reducing the number of filler fan units and / or eliminating the need for them to be placed on the mechanical housing. All fillers and fans are preferably integrated into the air treatment unit, which also includes corresponding piping, such as centralized exhaust piping. Furthermore, directional air conduction without pressure cascades is facilitated.

[0028] Preferably, the bottling line is located outside the second and third cleanroom housings and includes joining means for joining the transport path to a common outlet conveyor for upright transport of filled and sealed bottles. In this way, the bottles can be combined in a relatively slow outlet stream for subsequent labeling.

[0029] The joining mechanism can increase capacity by connecting the filling machines in parallel when the same product is being bottled in both machines. Bottles filled in the same manner can flow out as a uniform stream of bottles. Here, the space requirements for the filling machines and bottle outlets can be kept low.

[0030] Alternatively, the blow molding machine, the transport path including the filling machine, and the distribution unit are housed in a single common cleanroom housing. This reduces the amount of equipment required and allows for easier access and more flexible placement of individual assemblies.

[0031] Preferably, the bottling line further includes joining means located within a common cleanroom housing to join the transport route to a common outlet conveyor so that filled and sealed bottles are transported upright. In this case, the bottles require only one cleanroom lock on the outlet side.

[0032] The partial streams guided along the transport path can generally be discharged separately, for example, to be sent to different labeling machines.

[0033] Preferably, the bottling line includes partial outlet conveyors for the upright transport of filled and sealed bottles, each located downstream of the filling machine and height-adjustable at least on the inlet side. This allows for easy adaptation of the bottle outlet size to the height of each bottle.

[0034] Next, in the area of ​​the upstream closure device, an automatically adjustable guide element for the bottle can be provided, particularly in the form of a replaceable mounting fixture.

[0035] The exit conveyor and / or connecting means may be part of the machine block, or they may be embodied as units that have essentially independent functions and are connected to it.

[0036] Preferably, the split star wheel includes a clamp that can be actively opened by a moving element circulating over it and associated fixed moving elements. The moving elements associated with the first transport path are then positioned on a first common operating level, and the moving elements associated with the second transport path are positioned on a second common operating level above or below the first operating level. The moving elements are then positioned to be able to operate independently with respect to the operating levels.

[0037] In other words, fixed operating elements at the first operating level cooperate only with cyclic operating elements at the first operating level, and fixed operating elements at the second operating level cooperate only with cyclic operating elements at the second operating level. This allows for a space-saving and easy-to-design division of the stream by selectively releasing the clamp at either the first transfer point to the first transport path or the second transfer point to the second transport path.

[0038] A cyclic operating element is, for example, a cabinet lock that is rotatable around a vertical axis. A fixed operating element is designed as, for example, an operating cam, which rotates the cabinet lock around the vertical axis by collision with the cabinet lock in order to operate the clamp. This is primarily known from the transport star wheel for operation at a single level of operation.

[0039] Essentially, other designs of split star wheels are also conceivable, such as a switchable star wheel with a switchable radial cam, a shift star wheel with radially shifting clamps, and a transport star wheel with a circumferentially extending linear motor system for individual clamps.

[0040] Preferably, each conveying path is equipped with a pitch-reducing star wheel, which reduces a first conveying pitch just before splitting the bottle stream during bottle filling to a second conveying pitch smaller than the first conveying pitch.

[0041] Next, a pitch-reducing star wheel is preferably positioned immediately after a split star wheel, which then receives the bottles and, during further rotations around itself, changes the first conveying pitch, and in particular, produces a second conveying pitch in the process.

[0042] Pitch reduction star wheels can also be implemented as switching star wheels with switchable radial cams, shift star wheels with radially shifting clamps, and transport star wheels with circumferentially extending linear motor systems for individual clamps.

[0043] This allows for a relatively compact division of the bottle stream, while simultaneously enabling an adapted transport pitch and relatively high transport speeds. Here, the transport pitch is adapted while maintaining the individuality of the containers, i.e., maintaining a distance between them.

[0044] Furthermore, the bottling line preferably includes a central product dispenser that supplies a common product stock to the filling machine, particularly a central product dispenser that supplies a common cap stock to the filling machine, particularly a central cap dispenser that supplies caps to the capping machine associated with the filling machine, particularly a central cap dispenser that supplies caps from the stock reservoir.

[0045] A product distributor is, for example, a so-called valve manifold through which the product is directed to the individual filling valves of a filling machine.

[0046] A cap-closing distributor is, for example, a cascaded arrangement of feed channels leading from a stock reservoir to a cap-closing machine.

[0047] Such distribution of products and / or caps reduces space requirements for product and cap stocks and facilitates the supply and replenishment of each stock.

[0048] Furthermore, the bottling line preferably includes a central cleaning unit for CIP cleaning of the filling machine or machine block, along with a central cleaning agent supply and return.

[0049] Preferably, the bottling line further includes a control device that controls the filling machine together and / or synchronizes the control of a control unit provided on the filling machine. The synchronization of the controls includes, for example, type-specific parameter transfers, particularly relevant to products that are to be filled uniformly. This facilitates the control and operation of the filling machine.

[0050] For example, product type parameters can be transferred from one filling machine to another, requiring only one (common) input or similar operation steps. Nevertheless, each filling machine can have an independent operation unit and / or display unit. The inputs made there can then be applied to each other filling machine in a duplicate / mirror manner.

[0051] Through such common control, the filling machine is fully represented and / or addressed as a single processing unit (filling machine) within the operational concept of the machine block. By associating the corresponding shift registers of each control device, it becomes possible to control the blow position (blow mold) of the blow molding machine with the filling position (filling element) of the filling machine.

[0052] The common control device and / or individual control units of the filling machine can be located, for example, in a single common switching cabinet.

[0053] Common control of the filling machines enables a clear association between the blow position (blow mold) and filling position (filling element) used for each bottle, allowing for traceability of filled bottles throughout the value-added chain of the bottling line. Furthermore, it is possible to associate at least one labeling machine located downstream with the labeling position located therein.

[0054] A bottling line, particularly a common control device, preferably includes a central base unit for controlling the inspection systems at the exits of both transport paths. Such a control device may primarily include the following known functions: full pack inspection of the filling and closing machines. For example, this includes: • Filling height inspection (using high-frequency, infrared, camera, gamma-ray, or X-ray technology); • Detection of closures and tamper-evident seals (using sensor and camera technology); • Management of filling machines; • Production management; ·Quality control; And, • Safety management and / or adjustment of guide rails and / or inspection height.

[0055] Preferably, the bottling line further comprises a heating module upstream of the blow molding machine for heating the preforms, and a deembryonic unit positioned between the blow molding machines for deembryonicizing the preforms.

[0056] The heating module is preferably equipped with a shut-off star wheel on the inlet side to release and shut off the feeding of the preform in a controlled manner, and the shut-off star wheel is preferably driven by a stepper motor. The stepper motor enables, on the one hand, clock-accurate release and feeding, and on the other hand, shut-off and holding of individual preforms, for example, when a second blow position of the blow molding machine should not be fitted, or when it is fitted only for each second blow position.

[0057] For example, compared to known air-blocking units, the precise control and movement of the stepper motor allows control signals to the stepper motor to be directly registered in each mechanical shift register, thus enabling control of the preform feed without requiring additional sensing mechanisms for the presence of the preform or bottle. Furthermore, the effort required to set up and inspect corresponding sensors, which previously had to be precisely set up and frequently checked due to relatively high transport speeds, is eliminated.

[0058] The described method is useful for aseptically bottling liquid products, especially beverages, into bottles or similar containers.

[0059] The bottles are manufactured using a blow molding machine and divided into at least one first and second substream, each substream being filled into a separately associated filling machine.

[0060] The bottles are transported and handled under sterile conditions within a single machine block from manufacturing to filling. Furthermore, bottling is achieved in at least one transport path within a filling machine of the type with a central star wheel column and a support plate filler. This provides the effects described in claim 1.

[0061] After being uniformly filled, that is, using the same product, the bottles are rejoined in the same stream of bottles flowing out within the filling machine.

[0062] Due to the different filling processes in the filling machines for each product, the bottles can also flow out as separate streams.

[0063] Preferably, the first transport pitch generated by the splitting of a single-orbit stream of bottles is reduced by pitch reduction to a second transport pitch for filling bottles in the transport path. This means that during the circulating transport of bottles, the transport pitch of the partial stream is reduced by pitch reduction before filling.

[0064] Preferably, the partial stream is further transported under sterile conditions after bottling until it is joined to at least a common outlet stream. In a more advantageous embodiment, after bottling, the partial stream is discharged separately from the area of ​​sterile handling and then joined to a common outlet stream.

[0065] The combined output stream, along with the separately discharged substreams, can be sent to the labeling machines in a way that is advantageous to them, or to each labeling machine that is individually relevant.

[0066] Preferably, the filling machines are controlled together by an operator inputting uniform product type parameters and by applying the product type parameters to the filling machines from a single common control device, particularly by automatically transferring them from one filling machine to another. [Brief explanation of the drawing]

[0067] Preferred embodiments of the present invention are shown in the drawings. [Figure 1] Figure 1 is a schematic plan view of the bottling line in the first embodiment. [Figure 2] Figure 2 shows a schematic plan view of the distribution mechanism. [Figure 3] Figure 3 shows a side view of the segmented star wheel. [Figure 4] Figure 4 is a schematic plan view of the bottling line in the second embodiment. [Figure 5]Figure 5 is a schematic plan view of the bottling line in the third embodiment. [Figure 6] Figure 6 shows a schematic plan view of the inlet area of ​​the heating module in the bottling line.

[0068] Detailed explanation

[0069] As can be identified in Figure 1, in the first embodiment, the aseptic bottling line 1 includes a machine block 2 and at least one cleanroom housing 3 surrounding it. The machine block 2 comprises a blow molding machine 4, two filling machines 5, 6 and a distribution means 7, the distribution means 7 dividing a single-track stream of bottles 8 into a first partial stream 9 along a first transport path 9a using the first filling machine 5 and into a second partial stream 10 along a second transport path 10a using the second filling machine 6.

[0070] The single-orbit stream of bottles 8 consists of bottles 8a manufactured by the blow molding machine 4 at a continuously circulating blow position 4a (only one of each is shown). The distribution means 7 includes a continuously circulating transport position 7a. See also Figure 2.

[0071] The machine block 2 is characterized in that both the single-track stream of bottles 8 and the substreams 9 and 10 formed therefrom are transported exclusively and individually at coordinated distances from each other by a star-shaped transport means 11, such as a transfer star wheel. This results in a monoblock configuration of the blow molding machine 4, filling machines 5 and 6, and dispensing means 7.

[0072] At least one, preferably both, of the filling machines 5, 6 is embodied as a support plate filler having filling positions 5a, 6a that circulate on a conveying star wheel (only one of each filling position is shown). This means that, in contrast to a carousel filler having a container carousel, bottles are handled in the support plate filler, in particular, by neck handling on a star wheel that is continuously rotatably mounted on a support plate by a star wheel column. In contrast to a carousel filler, the support plate filler does not include, along with its filling structure, an internally isolated sterile area, such as an area isolated by a liquid lock, around the filling positions 5a, 6a, but in this respect, it can be freely positioned around each cleanroom.

[0073] The distribution means 7 comprises a split star wheel 12 and, preferably, pitch-reducing star wheels 13 and 14 that follow directly thereto.

[0074] In this regard, as identified in Figure 2, the split star wheel 12 preferably comprises a plurality of first clamps 15 uniformly distributed circumferentially thereon, the plurality of first clamps 15 which transport each second bottle 8a (e.g., bottles with irregular ordinal numbers) in a single-track stream of bottles 8 to a first transport path 9a for forming a first substream 9, and transport bottles 8a positioned between each of the streams of bottles 8 (i.e., those with even ordinal numbers) to a second transport path 10a for forming a second substream 10. The total number of clamps 15, 16 corresponds to the transport positions 7a of the bottle distribution means 7. The pitch-reducing star wheels 13, 14 are provided with clamps 13a, 14a corresponding to each second transport position 7a.

[0075] In this regard, as further specified in Figure 2, the pitch-reducing star wheels 13 and 14 have first transport pitches 13b and 14b in the transport of bottles 8a. This corresponds to twice the transport pitch of the split star wheel 12, in the sense that the clamp 13a of the first pitch-reducing star wheel 13 corresponds to the first clamp 15 of the split star wheel 12, and the clamp 14a of the second pitch-reducing star wheel 14 corresponds to the second clamp 16 of the split star wheel 12 (or vice versa).

[0076] The pitch-reducing star wheels 13 and 14 are embodied in reducing the transport pitch of the first and second partial streams 9 and 10 with respect to the first transport pitches 13b and 14b to a second transport pitch (not shown) which preferably corresponds to the transport pitch (not shown) of the filling positions 5a and 6a of the filling machines 5 and 6.

[0077] The first clamp 15 of the split star wheel 12 is preferably released in a controlled manner at the first transfer point 17 with the first pitch-reducing star wheel 13, as described later, and the second clamp 16 of the split star wheel 12 is correspondingly released at the second transfer point 18 with the second pitch-reducing star wheel 14, and the bottles 8a are then transported to the transport paths 9a and 10a in the process, respectively.

[0078] Furthermore, an optional first discharge means 19 for the first partial stream 9 and an optional second discharge means 20 for the second partial stream 10 are schematically shown to selectively discharge the bottles 8a from the transport paths 9a and 10a in the event of failure of the associated fillers 5 and 6, respectively. It is also conceivable to provide a discharge means between the blow molding machine 4 and a distribution means 7 (not shown).

[0079] Figure 3 shows a preferred operating mechanism for the first and second clamps 15 and 16. Thus, the split star wheel 12 comprises a first circulating operating element 21 associated with each first clamp 15 and a second circulating operating element 22 associated with each second clamp 16. The operating elements 21 and 22 are preferably embodied as cabinet locks rotatable about vertical axes 21a and 22a, and their rotation causes the associated clamps 15 and 16 to open (or close, depending on the direction of rotation).

[0080] The cabinet lock (circular operating element 21) associated with the first clamp 15 is located at the first common operating level 23, and the cabinet lock (circular operating element 22) associated with the second clamp 16 is located at the second operating level 24, which is offset upward (or downward) to isolate the control.

[0081] This means that because the distance 25 between operating levels 23 and 24 is very large, at least one fixed (non-circulating) operating element 26 located at the first operating level 23 is embodied as, for example, a control cam to operate only the cabinet lock at the first operating level 23, thereby operating the first clamp 15, and at least one fixed operating element 27 located at the second operating level 24 (for example, the control cam hidden in Figure 2) operates only the cabinet lock 22 at the second operating level 23, thereby operating the second clamp 16.

[0082] Fixed operating elements 26, 27 (control cams) for releasing clamps 15, 16 are positioned on the split star wheel 12 within the region of transport points 17, 18.

[0083] Having circulating operating elements 21, 22 and fixed operating elements 26, 27, such an operating mechanism allows for a relatively simple structure and space-saving division of the bottle 8 stream. Thus, reliable switching of clamps 15, 16 in the area of ​​each transport point 17, 18 at high transport speeds is provided.

[0084] In Figure 1, the closing machines 29 and 30, each located within a block, can also be identified with the partial outlet conveyors 31 and 32 located downstream by a transfer star wheel 11, which essentially forms the end of the outlet-side transport paths 9a and 10a, along with the filling machines 5 and 6 for closing the bottles 8a within their respective partial streams 9 and 10.

[0085] The partial outlet conveyors 31 and 32 are embodied, for example, as conveyor belts for transporting upright bottles, and are preferably height-adjustable at least on the inlet side. This facilitates easy size adjustment when transporting bottles by neck handling.

[0086] The transport paths 9a, 10a or partial outlet conveyors 31, 32 optionally connect to a common outlet stream 8' of bottles 8a on a common outlet conveyor 34, which has, for example, at least one conveyor belt for upright bottle transport, by connecting means 33 such as a distribution guide or similar transport-related combination.

[0087] The outlet flow 8' typically consists of bottle 8a, the first single-orbital stream of bottle 8, but is a multi-orbital stream and is correspondingly slower than that.

[0088] For example, a discharge table (not shown) used for inspecting and discharging bottles 8a from the outlet stream 8' can be located, for example, within the area of ​​the common outlet conveyor 34. Essentially, separate discharge tables can also be provided for each of the partial outlet conveyors 31 and 32. Each discharge table contains a collection container (unfilled) for the discharged bottles 8a. An inspection unit (not shown) can be associated with each discharge table.

[0089] The filled bottles 8 exit the area enclosed by the cleanroom housing 3 on the exit conveyor 34 through the (diametrically shown) cleanroom locks 35 associated with both filling machines 5 and 6. However, as can be identified in Figure 4 in this regard, each of the cleanroom locks 35 and 36 can be associated separately with the filling machines 5 and 6.

[0090] In this case, since there is no joining means 33 and a common outlet conveyor 34, the partial streams 9 and 10 can be discharged downstream separately and processed in, for example, two independent labeling machines (not shown). In contrast, the discharged common outlet stream 8' is preferably supplied to a single labeling machine (not shown).

[0091] As shown in Figure 1, the bottling line 1 further comprises a heating module 37 for preforms 8b associated with the inlet-side blow molding machine 4, and a deembryonic unit 38, the deembryonic unit 38 positioned between the heating module 37 and the blow molding machine 4, and deembryonic the preforms 8b by, for example, an electron beam or H2O2. The deembryonic unit 38 is shown schematicly only and can be positioned in the area of ​​the transfer star wheel 11 mainly by known methods.

[0092] The housing surrounding the deash unit 38 (as schematically shown) can be connected to the cleanrooms 3,3a surrounding the blow molding machine 4 on the ventilation side. For this purpose, an independent ventilation system could be considered, for example, to extract the steam generated during degermination.

[0093] In the normal production operation of bottling line 1, the preforms 8b and bottles 8a are nominally transported and processed by a fully occupied transport system. That is, one preform 8b is inserted into every circulating blow position 4a, and one bottle 8a is inserted into every transport position 7a and every filling position 5a,6a of the dispensing means 7.

[0094] The bottling line 1 is embodied for a fully occupied transport system, but variations are possible, for example, for other operating methods in the event of failure or replacement of one of the fillers 5, 6. In this case, a preform 8b can be temporarily inserted at each second blow position 4a of the blow molding machine 4, so that the blown bottles 8a are guided to each stationary transport path 9a, 10a via the distribution means 7 at each second transport position 7a.

[0095] The distribution means 7 may instead be equipped with a divided star wheel 12 in the form of a sliding star wheel, a pitch-reducing star wheel, or the like. In this case, the reference diameter and / or conveying pitch of the divided star wheel 12 changes during the circulation of bottles 8a to divide the stream of bottles 8 into first and second partial streams 9, 10, in which case, for example, the clamps 15, 16 of the divided star wheel 12 prevent collision with clamps 13a, 14a that are not associated with the subsequent pitch-reducing star wheels 13, 14 or the transfer star wheel 11, respectively, and further / or the pitch reduction is already performed on the divided star wheel 12.

[0096] For this purpose, the clamps 15 and 16 of the split star wheel 12 are appropriately pivotable, shiftable, and / or movable relative to the split star wheel 12, i.e., in or against the direction of their circulation, in order to transport bottles 8a at the transport points 17 and 18 and thereby avoid collisions between unrelated assemblies (transporting bottles 8a at each of the other transport points 17 and 18).

[0097] For a better overview, Figure 1 omits some components of the system essential for aseptic bottling, such as product supply, cleanroom ventilation, and machine control. In this regard, please refer to Figures 4-6. It will be understood that features described and / or expressed only once may be present in all embodiments of bottling line 1.

[0098] Figures 4 and 5 show alternative configurations for bottling line 1. The corresponding reference numbers are used for individual assemblies and product streams, so the corresponding structures and functions are again not illustrated. Furthermore, these arise from situations where reference numbers are omitted.

[0099] According to Figure 4, a product distributor 41 is preferably present for the common supply of product to the filling machines 5 and 6, which are connected on the inlet side to a product tank 42 having a common product stock 43 and on the outlet side to the filling machines 5 and 6 via supply lines 44 and 45. Within this, the liquid product is distributed to individual filling elements at filling positions 5a and 6a mainly by known methods. Thus, the product distributor 41 can be considered as a central valve manifold for the filling elements. The product stock 43 can also be held so that it can be obtained from other central containers or lines via the central product distributor 41 / valve manifold.

[0100] Furthermore, the bottling line 1 includes a central air treatment unit 46 connected to the cleanroom housing 3 via a ventilation conduit 47 to generate a cleanroom atmosphere suitable for aseptic bottling. Individual methods and devices for such air treatment are known and are therefore not illustrated in detail.

[0101] Figure 4 shows the closing machines 29 and 30 associated with the filling machines 5 and 6, and an optional closing cap distributor 51, which is connected to a stock reservoir 52 having a closing cap stock 53 on the inlet side and to the closing machines 29 and 30 via feed channels 54 and 55 on the outlet side.

[0102] The closed cap distributor 51 can be integrated, for example, into a cascaded structure of feed channels 54 and 55, which are embodied with appropriate inclines for transporting closed caps to the closed cap machines 29 and 30. Furthermore, the closed caps can be degerminated particularly efficiently in the region from the storage reservoir 52 to the closed cap distributor 51, mainly by known methods.

[0103] The amount of equipment and operational effort required to continuously supply product stock 43 and closed cap stock 53 by product dispensers 41 and / or closed cap dispensers 51 for filling machines 5 and 6 can be reduced compared to separate storage for each individual filling machine 5 and 6.

[0104] Figure 5 shows a modified example of the bottling line 1 based on the embodiment shown in Figure 4, in which separate cleanroom housings 3a, 3b, and 3c forming the cleanroom housing 3 of the machine block 2 are provided on the one hand for the blow molding machine 4 and the distribution unit 7, and on the other hand for each of the filling machines 5 and 6.

[0105] Next, the central air treatment unit 46 is connected via a first ventilation conduit 47 to a first cleanroom housing 3a surrounding the blow molding machine 4 and distribution unit 7, via a second ventilation conduit 48 to a second cleanroom housing 3b surrounding the first filling machine 5, and via a third ventilation conduit 49 to a third cleanroom housing 3c surrounding the second filling machine 6.

[0106] As a result, the filled bottles 8 are discharged from their respective cleanroom housings 3b, 3c through separate cleanroom locks 35, 36 as partial product streams 9, 10. Downstream, the partial product streams 9, 10 may be joined together or separately and further processed (not shown), i.e., they may be labeled together or separately.

[0107] The separate cleanroom housings 3a, 3b, and 3c allow for uninterrupted production operation by partially utilizing the bottling line 1 when one of the filling machines 5 or 6 is not in operation for inspection purposes.

[0108] Next, the central air treatment unit 46 enables flexible and economical air treatment within the cleanroom housings 3a, 3b, and 3c, which are each used for production.

[0109] This also applies to the aforementioned central product distribution to filling machines 5 and 6, which is also possible without limitation by separate cleanroom housings 3a, 3b, and 3c.

[0110] The bottling line 1 preferably includes a central CIP unit for cleaning the filling machines 5 and 6, and a sterile equipment area of ​​the filling machine block 2. The CIP unit can operate in accordance with well-assured principles for the sterile production area and is therefore not indicated or described in detail.

[0111] Figure 5 shows a variation of the bottling line 1, representative of other described embodiments, which allows the filling machines 5 and 6 to be combined into a single product unit and operate toward each other in terms of conveyance. A common control device 61 with input and output units 62, such as a touchscreen, and control units 65 and 66, which are present in or otherwise related to the blow molding machines 5 and 6, are schematically shown as examples. The control units 65 and 66 can also control, for example, the closing machines 29 and 30 associated with the filling machines 5 and 6, mainly in known ways.

[0112] The common control device 61 and the lower-level control units 65 and 66 form a control module 67, which can be coupled to the higher-level control system 68 of the bottling line 1 to operate as a single production unit.

[0113] Therefore, the filling machines 5 and 6 can be treated as a single machine with respect to control, especially for bottling one and the same product, and can be operated with only one input and output device 62 in a simple manner. This not only facilitates the operation of the filling machines 5 and 6 but also enables common storage of product type parameters in a common control device 61 and simple transfer of such product type parameters to the filling machines 5 and 6. This means that operational errors due to any different inputs to the filling machines 5 and 6 can be avoided and the association of product type parameters to the filling machines 5 and 6 can be automated.

[0114] It is also conceivable to implement the common control device 61 in one of the control units 65, 66, and / or to automatically associate the common control device 61 with the control devices 65, 66 to which input is received.

[0115] Product type parameters can be automatically transferred between the control units 65 and 66 of the filling machines 5 and 6. Which of the above operator concepts is advantageous in each case depends, for example, on the spatial arrangement of the filling machines 5 and 6 within the machine block 2, and / or on the equipment of the individual filling machines 5 and 6, including their input and output units 62.

[0116] Figure 6 shows a preferred modification of the heating module 37, in which a shut-off star wheel 91 is present on the inlet side, driven by a stepper motor 92 (hidden in Figure 6). The shut-off star wheel 91 helps to mechanically release and shut off the feeding of the preform 8b to the heating module 37. Similarly, the feeding of the preform 8b can be timed by the stepper motor 92 so that the preform 8b is fitted only at each of the second circulating heating positions 37a of the heating means 37 (only one of which is shown), and thus also at each of the second circulating blow positions 4a of the blow molding machine 4.

[0117] The shut-off star wheel 91 is preferably positioned upstream of the zigzag star wheel 93, thereby creating a transport pitch for the preform 8b that coincides with the circulating heating position 37a.

[0118] Here, the stepper motor 92 enables the precise, controlled, and easy-to-handle feeding of the preform 8b. This allows for faster and more accurate feeding than known pneumatic shutoff devices. On the other hand, the precise feeding of the preform 8b, with highly reliable control by the stepper motor 92, eliminates the need to verify whether each circulating heating position 37a is occupied by the preform 8b. This means that the stepper motor 92 enables the precise and reliable feeding of the preform 8b, making efforts both with additional sensors for controlling the heating positions 37a and the associated equipment and heating module 37 configurations essential.

[0119] Bottling line 1 operates as follows:

[0120] In normal production operations, product type parameters for bottling a particular product are preferentially input to both filling machines 5 and 6 via a common control device 61, then transferred from the latter to the control units 65 and 66 of the filling machines 5 and 6, where they are used in subsequent production operations using a fully dedicated transport system.

[0121] Product type parameters can be transferred between filling machines 5 and 6, resulting in only one common input being required.

[0122] For this purpose, the common control device 61 and / or separate control units 65, 66 of the filling machines 5, 6 can optionally be used with respect to the control system 68 of the bottling line 1, either with a common or separate indicator.

[0123] In this way, the shift register can be divided among the replicated filling machines 5 and 6, and the production data of the bottles 8a can be associated with each filling machine 5 and 6 used.

[0124] Along the production chain of bottling line 1, a clear association between the blow mold and the filling element is possible in terms of the traceability of bottle 8a.

[0125] The preform 8b is continuously fed to all heating positions 37a of the heating module 37, and a single-orbit stream of bottle 8 is produced by blowing the bottle 8a at all blow positions 4a of the blow molding machine 4.

[0126] The stream of bottles 8 is continuously sent to the distribution means 7. At each second transport position 7a, bottles 8a are alternately distributed to the first transport path 9a and the second transport path 10a.

[0127] In the event of a failure or prolonged production interruption in one of the transport paths 9a, 10a, the bottles 8a can also be distributed by a switching star wheel by activating a radial cam so that all bottles 8a in the stream of bottles 8 are deflected to their respective undisturbed transport paths 9a, 10a. The blow molding machine 4 can then operate at half speed in a fully occupied blow position 4a.

[0128] In the transport paths 9a and 10a using the fully occupied transport system, the initial transport pitches 13b and 14b are reduced to the transport pitches of the filling machines 5 and 6.

[0129] This reduces the speed and conveying speed of subsequent units, minimizing the problem of spillage of filled products. Furthermore, the mechanical performance of 36,000 bottles per hour, which is the maximum required after splitting the conveying paths 9a and 10a, i.e., the original bottle 8 stream, can also be handled by support plate fillers, which are primarily advantageous in aseptic production areas.

[0130] Partial streams 9 and 10 are filled into filling machines 5 and 6 at all filling positions 5a and 6a, and then closed by subsequent closing machines 29 and 30.

[0131] The filled partial streams 9 and 10 can be discharged separately after joining their respective cleanroom housings 3, 3b, and 3c, or they can be labeled as a common outlet stream 8' or as separate downstream partial streams 9 and 10, mainly in known ways.

[0132] In the event of a failure or defect in filling machines 5 or 6, selective introduction of each second preform 8b into the heating module 37 is possible, and thus filling machines 5 or 6 that are still functioning correctly can continue bottling. For this purpose, it is also conceivable to temporarily discharge each second preform 8b downstream of the fully occupied heating module 37.

[0133] If filling machines 5, 6 and / or closing machines 29, 30 fail, the shut-off star wheel 91 in the insertion section of the heating module 37 can be stopped / shut off. The bottles 8a and preforms 8b associated with this filling machine 5, 6 can then be discharged, while the other filling machine 5, 6 continues production.

[0134] Bottles 8a associated with the filling machines 5,6 that have defects are preferably discharged downstream of the split star wheel 12. To avoid collision with the subsequent pitch-reducing star wheels 13,14, these preferably rotate at all times. The bottles 8a can then be discharged by the pitch-reducing star wheels 13,14, and, if additionally, by the transfer star wheel 11.

[0135] The bottling line 1 and aseptic bottling method have been described with reference to the preference for dividing a single-orbit stream of bottles 8 into two substreams 9, 10 or transport paths 9a, 10a. However, multiple streams of bottles 8 and / or more substreams 9, 10 or transport paths 9a, 10a are conceivable by parallel or series connections of, for example, a split star wheel 12 and a pitch-reducing star wheel 13, 14 that pick up a corresponding number of bottles 8a.

[0136] The stream of bottles 8 consists of bottles 8a made of plastic, particularly PET, manufactured in the blow molding machine 4. However, it is also conceivable to divide any other or additional bottles 8a of at least one single-orbit stream of bottles 8 into partial streams 9,10 in the manner mainly described.

[0137] It is always essential for this purpose to divide the stream of bottles 8 into a fully occupied transport system immediately before filling bottles 8a, thereby achieving the aforementioned objective of improving the filling / closing of bottles 8a under sterile conditions.

[0138] Furthermore, the structural shape of the support plate filler enables a bottling line for aseptically bottling the product, and this bottling line can be configured particularly flexibly and modularly with little effort.

[0139] In this case, it is particularly advantageous to implement all filling machines 5 and 6 of bottling line 1 as support plate fillers.

Claims

1. A bottling line (1) for aseptically bottling liquid products, A machine block (2) comprising a blow molding machine (4) for manufacturing bottles and supplying them as a stream (8) of bottles, at least one first transport path (9a) and a second transport path (10a) each including one filling machine (5, 6) for filling bottles, and a distribution unit (7) for dividing the stream of bottles into transport paths in a fully occupied transport system so that the bottles can be continuously filled at all circulating filling positions (5a, 6a) of the filling machines, wherein in the fully occupied transport system, one preform (8b) can be inserted into all circulating blow positions (4a) of the blow molding machine (4), and one bottle (8a) can be inserted into all transport positions (7a) and all filling positions (5a, 6a) of the distribution unit (7), At least one cleanroom housing (3) surrounding the aforementioned machine block, Equipped with, At least one of the filling machines is embodied as a support plate filler having a support plate, a rotary drive unit, a star wheel column, and a filler carousel. A bottling line comprising a support plate formed by the bottom plate of a cleanroom housing (3), a rotary drive unit formed below the support plate, a star wheel column continuously driven by the rotary drive unit and extending through the support plate, a filler carousel resting on the star wheel column and comprising a clamp support with a clamp for receiving bottles (8) and a filling valve support with a filling valve, and the support plate further embossed for receiving the star wheel columns of an insertion star wheel and an outlet star wheel and / or subsequent closing machines (29, 30).

2. The bottling line according to claim 1, wherein the blow molding machine (4) and the distribution unit (7) are located in a first cleanroom housing (3a), the first transport path (9a) including the filling machine (5) is located in a second cleanroom housing (3b), and the second transport path (9b) including the filling machine (6) is located in a third cleanroom housing (3c).

3. The bottling line according to claim 2, further comprising an air treatment unit for supplying common air to the first cleanroom housing (3a), the second cleanroom housing (3b), and the third cleanroom housing (3c).

4. The bottling line according to claim 2 or 3, further comprising joining means (33) located outside the second cleanroom housing (3b) and the third cleanroom housing (3c), which joins the first transport path (9a) and the second transport path (10a) on a common outlet conveyor (34) to transport the filled and sealed bottles (8a) upright.

5. The bottling line according to claim 1, wherein the blow molding machine (4), the transport path (9a, 10a) including the filling machines (5, 6), and the distribution unit (7) are arranged within a single common cleanroom housing.

6. The bottling line according to claim 5, further comprising a joining means (33) disposed inside the common cleanroom housing, wherein the joining means joins the first transport path (9a) and the second transport path (10a) to a common outlet stream (8') of the bottles (8a) on an outlet conveyor (34) for transporting the filled and closed bottles (8a) upright.

7. A bottling line according to any one of claims 1 to 6, further comprising partial outlet conveyors (31, 32) for upright transport of filled and sealed bottles (8a), wherein each of the partial outlet conveyors (31, 32) is located downstream of the filling machines (5, 6) and is height adjustable at least on the inlet side.

8. A bottling line according to any one of claims 1 to 7, further comprising a central product dispenser (41) for supplying products to be filled from a common product stock (43) to the filling machines (5, 6) and / or a central cap dispenser (51) for supplying caps from a common stock storage (52) to capping machines (29, 30) associated with the filling machines.

9. The bottling line according to any one of claims 1 to 8, wherein the distribution unit (7) is equipped with a split star wheel (12) that alternately transports each second bottle (8a) of the bottle (8) stream in the first transport path (9a) and the second transport path (10a).

10. The bottling line according to claim 9, wherein the segmented star wheel (12) comprises clamps (15, 16) that can be actively released by operating elements (21, 22) circulating on the segmented star wheel (12) and associated fixed operating elements (26, 27), the operating elements (21, 26) associated with the first transport path (9a) are located at a first common operating level (23), and the operating elements (22, 27) associated with the second transport path (10a) are located at second common operating levels (24) above and below the first common operating level (23), and the clamps are operated independently with respect to the first common operating level (23) and the second common operating level (24).

11. A bottling line according to any one of claims 1 to 10, wherein each conveying path (9a, 10a) comprises at least one pitch-reducing star wheel (13, 14), and when filling the bottles (8), the first conveying pitch (13b, 14b) in the division of the stream of bottles (8) is reduced to a second conveying pitch smaller than the first conveying pitch.

12. A nucleation unit (38) for removing nuclei from a preform (8b) is connected to the upstream side of the blow molding machine (4) in the bottling line according to any one of claims 1 to 11.

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