A SUSTAINABLE AND ENVIRONMENTALLY FRIENDLY SMART FILM COATING SYSTEM AND METHOD FOR PREVENTING MICROBIAL CONTAMINATION IN ALUMINUM BEVERAGE CANS.

Abstract

The invention relates to a coating system and method developed to ensure hygiene on the lid (12) and the upper side surface (11) of aluminum beverage cans (10). The system includes a labeling machine (20) that applies a label (21) to the upper side surface (11) of the cans (10), a coating machine (30) that applies the coating material (31) to the lid (12) and / or the upper side surface (11), a perforating machine (60) that creates a perforation line (62) on the coating, and a laser (61). The applied coating layer (31) ensures hygiene, while the perforation line (62) allows the consumer (C) to easily peel off the coating. The system may also include a drying machine (40) for post-coating curing, a cooling machine (50) for cooling, and a cooling tunnel (51). Thus, the invention presents an innovative coating system that ensures hygiene on the surfaces of cans (10), is easily peelable, and can be integrated into production lines.

Description

1 TARIFF MICROBIAL CONTAMINATION IN ALUMINUM BEVERAGE CANS A SUSTAINABLE AND ENVIRONMENTALLY FRIENDLY SMART FILM FOR PREVENTION. COATING SYSTEM AND METHOD 5 Technological Field: The invention relates to the mouth of aluminum beverage cans, including the lid and radius section. Smart film 10 applied to ensure hygiene in areas that will come into contact This relates to the coating system and the method of applying this coating. State of the Art: Today, aluminum beverage cans are preferred for their practicality and cost advantages. They are widely used. However, these boxes, from production to consumption... During this process; filling lines, storage areas, logistics chain and market shelves Because they are exposed to different environmental conditions, such as those mentioned above, their upper surfaces and especially There is a serious risk of microbial contamination in the lid areas that will come into contact with the mouth. It carries. 20 The hygienic lid solutions currently available on the market are generally heat-sealed. These products come in the form of aluminum foil. However, there are some important considerations when using these products. Disadvantages are emerging. The current aluminum hygienic lid In the solutions, due to the excessive adhesive force, 25 during the opening of the product. consumers experienced difficulties, and when the opening process was complete, a mark appeared on the lid surface. It is known that foil or film residue remains. On the other hand, it is easy to open. In lids designed in this way, products are placed on market shelves or in refrigerators. The lids lift up on their own while waiting, thus improving hygiene. Problems such as losing arise. 30 2 In addition to these problems, laboratory studies have shown that randomly collected Aluminum beverage cans reach levels of 10⁴ – 10⁵ CFU / cm² on their top surfaces. The presence of microbial loads reaching the containers was detected. Indeed, on 194 boxes... ATP analyses revealed that 46.39% of the boxes were hazardous and unhygienic. 30.93% are inappropriate, 30.93% require caution, and only 22.68% are 5 It has been classified as clean. This data refers to the top of aluminum beverage cans. their surfaces are mostly not hygienic and due to direct mouth contact This indicates that it poses a risk to public health. Furthermore, in experimental studies regarding box lid contamination; E. 10 After hands contaminated with E. coli come into contact with wet and dry containers, wet Microbial transfer rate exceeding 50% in boxes and over 30% in dry boxes. This finding indicates that consumers carry the boxes they buy from the market by hand. simple everyday things like placing it on the conveyor belt or touching it when taking it out of the cupboard This reveals that even the processes themselves pose a serious risk of contamination. 15 On the other hand, in existing hygienic coating solutions, the radius (lid and box) The area between the curved passage (between the body and the lid) is usually not preserved, only the cover remains. The surface is covered to a limited extent. However, during lip contact, the consumer both The cover also makes contact with the radius region. Additionally, the existing film or foil is 20 In peel-based solutions, peelability performance is not stable; some products exhibit excessive Due to adhesion, the film tears and leaves residue, and in some products... Because the adhesion is weak, the film opens up during production and logistics, thus It loses its hygienic properties. In addition, the materials used in current solutions are often recycled. non-recyclable, non-environmentally friendly plastic-based It consists of adhesive films. This situation reflects increasing sustainability expectations. and this creates a significant disadvantage in terms of environmental regulations. The PCT numbered WO2024154883A1 was encountered in the literature search. In the patent document, it is stated that the lid is designed to ensure the hygiene of the box lid. 3 it is attached to, and at the same time, the box can be opened by lifting the ring upwards. a removable hygiene cap made of synthetic resin material that facilitates ease of use This is explained. However, in this solution, the hygiene cover is only a mechanical one. It provides protection, leaving no antimicrobial film layer on the surface. It does not create a barrier, and after removal, the surface of the lid comes into contact with the external environment again. 5 Also, the lid may become dislodged during assembly or transport. the lid can be removed, allowing it to be reused and thus minimizing the hygiene risk. It has disadvantages such as causing problems. In conclusion, with the current technique, the entire mouth, including the lid and radius, is in contact with the skin. providing hygiene on their surfaces, and having controlled and stable peelability, also an environmentally friendly and recyclable coating solution The need remains. Brief Description of the Invention: 15 The invention solves the disadvantages of hygiene caps in the current state of the art. including the lid and radius of aluminum beverage cans that come into contact with the mouth. Smart film applicable to all regions, can be integrated into the production line. It describes the coating system and method. 20 The purpose of the invention is to provide hygienic protection simply by attaching a physical cover. instead, a transparent product is applied directly to the surfaces of the box that will come into contact with the opening. Provides lasting hygiene by forming a stable, antimicrobial, and peelable film layer. The goal is to create a new system that provides this. 25 The system described in the invention incorporates conveyor synchronization, product recognition sensors, and Thanks to software-controlled prescription, the area to be coated on each box (lid, The radius or fuselage is determined automatically. The servo-controlled system includes Multiaxial spray nozzles spray the coating material onto the designated area. 30 The applied coating is cured using UV, infrared, or hot air, depending on preference. 4 By drying through the units, a stable and durable film layer is formed on the surface. is created. Coating thickness can be precisely adjusted within the range of 10–500 microns. Thanks to inline thickness measurement sensors, it is controlled with a tolerance of ±1 micron. 5 The system, with optional cooling units, is used in high-speed film production lines. It ensures stabilization. In addition, thanks to the laser scoring unit, it applies pressure to the film. The exposed score line allows the consumer to easily peel the product. The invention is environmentally friendly, biodegradable and food-contact safe. By using coating materials with formulations, the existing hygiene the physical protection provided by the covers; chemical, microbial and user It takes the experience to a more advanced level. Explanation of the Figures: 15 The invention will be described by reference to the attached figures, so that the invention Its features will be understood more clearly. However, the purpose of this invention is not this specific one. It is not about limiting it with regulations. On the contrary, the invention's accompanying claims all alternatives, modifications that can be included within the area defined by 20 and the inclusion of their equivalencies is also intended. The details shown are only It is shown for the purpose of describing the preferred arrangements of the present invention and both the shaping of methods and the rules and concepts of invention to provide the most useful and easily understandable description of its properties It should be understood that they are presented. In these drawings; 25 Figure 1. In the system described in the invention, the labeling machine and the side surfaces of the boxes. View showing the application of a label to the top area. Figure 2 - The system described in the invention includes a coating machine with a spray nozzle. Coating on the lid and upper side surfaces of the boxes 30 View showing the implementation. Figure 3 - The system described in the invention includes a coating machine with a spray nozzle. Coating for the lid and upper side surfaces of the boxes Another view showing its implementation. Figure 4 - The system described in the invention includes a sponge-headed coating machine. Coating on the lid and upper side surfaces of the boxes 5 View showing the implementation. Figure 5 - Coating process with drying machine in the system subject to the invention. View showing the curing process of the cans. Figure 6 – Cooling machine and cooling tunnel in the system subject to the invention. View showing the cooling of the boxes. 10 Figure 7 - Coating with a perforated cutting machine in the system subject to the invention. A view showing the application of perforated cutting. Figure – 8 In the system subject to the invention, the coating is applied by the consumer's hand. An image showing how it can be peeled open using a specific method. Figure 9 - Box with opening for coating in the system subject to the invention 15 A view that shows its design. Figure – 10 In the system described in the invention, by holding the coating from the opening area The appearance of being peeled. Figures that will help understand this invention are shown in the attached image, number 20. They are numbered and their names are given below. Explanation of References: Box 10, 25 11. Upper region of the lateral surface 12. Cover 20. Label application machine 21. Label 22. Label roll 30 30. Coating machine 31. Coating 6 32. Spray nozzle 33. Sponge cap 40. Dryer 50. Cooling machine 51. Cooling tunnel 5 60. Perforated cutting machine 61. Laser 62. Perforation line 63. Opening area A. Direction of progress 10 B. Coating opening direction C. Consumer D. Movement platform Description of the Invention: 15 This invention applies to the lid (12) and side surface top of aluminum beverage cans (10). hygiene to all areas that come into contact with the mouth, including region (11). This relates to the smart film coating system and method developed to provide this. The system includes labeling, coating, curing, cooling, laser scoring, and quality control. 20 It has a modular structure consisting of units and is integrated into high-speed production lines. It is designed in a way that can be used. In the system described in the invention, the coating process will be applied to boxes (10). The can, usually made of aluminum, is a common 25 used for filling beverages. It is a cylindrical structure with a lid (12) on top, used as a container. Within the system, the labeling process is carried out on the upper side surface area of ​​the boxes (11). is made, then the cover (12) and the upper part of the side surface (11) are coated. layer (31) is applied. The applied coating layer (31) is cured. hardened in unit (40) cooling machine (50) and cooling tunnel 30 (51) is stabilized by passing through, then by perforated cutting machine (60) A perforated line (62) is opened on the coating layer (31) and the consumer (C) 7 It is prepared so that it can be easily peeled. The box (10) contains all these in the system. During the operations, the motion platform (D) moves in direction A and each The system is subjected to the relevant process at the station. The system has different volumes, diameters and It is designed to work with boxes of various heights (10). As shown in Figure 2, in the system that is the subject of the invention, the side surface top of the boxes (10) a labeling machine (20) that sticks (11) labels (21) to the region It includes: Labeling machine (20), labels (21), label roll (22) by taking it from the moving platform (D) the boxes (10) moving on the moving platform Apply the coating layer to be applied to the box (10) with the labels (21). (31) serves as a holding point for peeling. Alternatively, in the invention, without using a label (21) during the coating of a specific box (10) An opening tab can be created by leaving an unpaved area in this region. This In this method, the uncoated area is used as the holding point by the consumer (C). It is used and the coating layer (31) can be peeled off with the help of this tab. 15 The system in question is applied to the lid (12) and upper side surface (11) of the boxes (10). It includes a coating machine (30) that applies coating material (31). The coating machine can operate using different nozzle types. Figure 2 and As shown in Figure 3, the coating machine (30) uses the spray coating method 20 It can use servo-controlled multi-axis spray nozzles (32) It atomizes the coating material and sprays it onto the surface of the box (10). In this way, the lid (12) and the upper part of the side surface (11) of the box (10) are homogeneous and A film layer of controlled thickness is applied. Spray angle, spray quantity, and The duration can be dynamically adjusted via the software. 25 As shown in Figure 4, the coating machine in the invention (30) is for sponge coating. It can apply coating using this method. Accordingly, sponge coating. In this method, a sponge cap (33) can be used. The sponge cap (33) is a coating. Apply the material directly to the lid (12) and the upper side surface (11) of the box (10) 30 It spreads by contact. Especially where contact coating is required instead of spraying. It is preferred in formulations. 8 As shown in Figure 5, the coating machine in the invention (30) is used for coating. a drying machine that cures the coating layer (31) on the boxes (10) (40) contains. The dryer (40) removes the chemical coating material. Depending on its structure, it can be powered by UV, UV-LED, infrared, or hot air technologies. It can work. Its task is to cure the coating layer, making it stable, durable, and transparent. It is to bring. As shown in Figure 6, the system described in the invention undergoes coating and curing after... to reduce the surface temperature of the boxes (10) and the coating layer (31) 10 In order to ensure its stabilization, a cooling machine (50) and cooling It includes tunnels (51). Its tasks are to ensure the safe passage of the product to the next process. to ensure and maintain the integrity of the coating layer (31). As shown in Figure 7, in the invention, a perforated line 15 is placed on the coating layer (31). (62) includes a perforated cutting machine (60). Perforated cutting machine (60), by creating a discontinuous perforated line (62) with the help of a laser (61), the consumer (C) enables easy peeling off of the coating layer (31). Perforated cutting (60) alternatively different laser types or mechanical cutting on the machine systems can also be used. 20 The invention allows for peeling / opening during the coating process without the need for a label. For this purpose, on the coating layer (31), the consumer's mouth and completely outside the lip contact area, at the back of the drinking area a small opening area positioned and with increased thickness at the micron level 25 (63) is released. (Figure - 9) The opening area (63) is grasped by the consumer's (C) finger. A functional opening tooth that allows the coating layer to be easily removed. It is characterized by its software-controlled spraying capabilities. (Figure - 10) Thanks to its mechanism, the coating layer (31) only comes into contact with the lips and mouth. The areas can be limited to a certain allowance for overflow. Thus, 30 Significant savings in the use of coating layer (31) material. 9 while hygiene protection is not reduced in any way, at 100%. It is preserved. In the invention, the opening area (63) located on the coating layer (31), coating thickening of layer (31) or leaving “uncoated area” 5 This is ensured. If the "thickening" method is chosen, this point can be reached by any method. The coating material is applied in a controlled manner at a higher micron thickness, Thus, when held with a finger, it creates a lifting effect on the edge. Uncoated. If the "area" method is chosen, this point is left completely blank and the finger is used directly. The coating layer can be removed by contacting the box surface. The opening area in the invention is 10 (63) Circular or crescent-shaped with a diameter of approximately 3–6 mm can be designed. In the invention, the opening area (63) is the area of ​​contact of the consumer's mouth and lips. completely outside, on the lid (12), away from the drinking opening. It is located in this section. The perforated section mentioned earlier in the invention. The perforated line (62) opened by the machine (60) is 15 of this opening area (63). It is designed to start from the edge. Thus, the consumer can start from the opening area (63) By holding it, you can easily remove the coating along the perforated line (62). The coating material used in the invention (31) is water-based, solvent-based or UV-based. It can be based on. Its function is to create an antimicrobial, transparent, peelable film on the box surface. 20 The goal is to form a layer. Material formulation, different adhesion It can be optimized according to its characteristics. According to the invention, the coating Drying, curing and cooling processes depending on the type of material. An alternative version that is not needed can also be implemented. In this context, 25 self-drying coating formulations while walking The aim is to improve this approach, which involves equipment and components in the production line. It aims to reduce total costs by reducing energy requirements. The invention... The subject is the chemical formulation of the coating material, in the first version. Even if not implemented, versions that will be developed as soon as possible will be in nature. It is soluble, can be completely washed away in water, and under suitable conditions can be added to fertilizer at 30%. It will be designed to acquire transformative features. With this development... The aim is to maintain high hygiene performance while minimizing the environment after use. A coating that leaves no residue, is completely sustainable and environmentally friendly. The goal is to create a solution. In the system that is the subject of the invention, firstly, the label application machine (20) and the label Labels (21) taken from roll (22) are placed on the movement platform (D) 5 The boxes (10) are carefully glued to the upper side surfaces (11). Peeling off the coating layer (31) to be applied to the box (10) Labels (21) It serves as a holding point. Boxes where the labeling process is complete. (10) is transmitted to the coating station (A) in the direction of advancement. In the invention, the coating process is carried out via a coating machine (30). The aforementioned coating machine (30) can be fitted with a spray nozzle (32) or sponge as needed. Apply coating using the nozzle (33). Spray nozzle (32), servo coating material (31), cover (12) through controlled multi-axis nozzles and sprays onto the upper part of the side surface (11). The amount of spray, the angle and 15 The duration can be dynamically adjusted via software. Alternatively, The sponge head (33) used is the covering material of the cover (12) and the side surface. It spreads homogeneously by making direct contact with the upper region (11) and especially Preferred in formulations requiring contact coating instead of spraying. is being done. 20 Coating layer (31) thickness is measured using inline sensors to ±1 micron Precise feedback is provided to the dosing pump, enabling the desired film to be produced. The thickness is preserved. After the coating process, the boxes (10) are put into the drying machine. (40) is transferred. In the drying machine, depending on the type of coating chemical, 25 Curing is done using UV, UV-LED, infrared, or hot air technologies. and a stable, transparent and durable film layer is formed on the surface. Boxes (10) with completed curing process, cooling machine (50) and cooling It passes through the tunnel (51). This station has a surface temperature of 30°C on the lining layer (31). It balances and ensures film stabilization. 11 The cooled boxes (10) arrive at the perforated cutting machine (60). Perforated cutting perforated on the coating layer (31) with the help of the machine (60) and laser (61). line (62) is opened. Perforation line (62) is opened along the coating opening direction (B) of the consumer. (C) enables easy peeling off of the coating layer (31). Laser parameters, coating layer (31) precisely according to film thickness and material structure 5 By adjusting the settings, the process is carried out without damaging the underlying metal surface. In boxes where the coating application subject to the invention is made (10), consumer (C) coating peel off the coating layer (31) by hand along the perforation line (62). layer (31) retains its integrity during peeling and leaves residue on the surface 10 It does not leave any residue. This structure ensures that the beverage remains free from any contamination. It ensures that it is consumed in a hygienic manner. The system is environmentally friendly and has food contact compliance certifications from authorities such as the FDA and EFSA. 15 designed to work with biodegradable coating materials. It is designed to be modular and, thanks to its modular structure, compatible with existing filling lines. It can be integrated or used as a standalone unit. Throughout the process, the coating layer is examined with the help of high-resolution cameras. (31) Its thickness, homogeneity and peelability are constantly monitored. The system described in the invention has a function for determining the partial coverage area. It is located. Thanks to this function, the area to be coated (cover (12), side surface upper region (11) or areas such as the body) according to customer request It can be selected software-wise, and the relevant coating recipe is entered into the system. It can be uploaded. In case of product type changes, prescription information registered in the system 25 It is updated automatically and the coating machine (30), spray nozzle (32) or sponge head (33) positions, spray parameters and to be coated The fields automatically adjust according to the new product type. This structure allows for different products. It provides the possibility of rapid switching between variants and minimizes downtime in the production line. It reduces it to a minimum. 30

Claims

12 REQUESTS 1. The lid (12) and the upper part of the side surface of aluminum beverage cans (10) (11) a coating layer (31) to ensure hygiene It is a related method, and its characteristic is; 5 • moving the mentioned boxes (10) on a movement platform (D), • the lid (12) and side of the box (10) through a coating machine (30) A coating is applied to the surface top region (11) by applying a coating material. obtaining layer (31), • a perforated cutting machine (60) and laser 10 on the coating layer (31) It is characterized by opening the perforated line (62) with the help of (61).

2. This method complies with Claim 1 and its characteristic feature is that a label is applied before the coating process. by means of the gluing machine (20) to the top side surface of the boxes (10) (11) task of holding to make peeling off the coating layer (31) easier 15 The sign is to attach at least one label (21) to each person who sees it.

3. This method complies with Claim 1 and is characterized by its servo-controlled coating process. This is done using a multi-axis spray nozzle (32).

4. This method complies with Claim 1, and its characteristic feature is that the coating process is done with a sponge head. (33) is carried out using.

5. This method complies with Claim 1 and its characteristic feature is that the coating thickness is inline. Measured by sensors and returned to the dosing pump with an accuracy of ±1 micron. 25 It is about providing notification.

6. The method is compliant with Claim 1, and its feature is; box (10) instead of label (21) by leaving an uncoated area on the coating layer (31), 30 serves to hold the coating layer (31) in place to make peeling easier. The opening area (63) is to create. 13 7. The method is compliant with Claim 1, and its feature is; box (10) instead of label (21) on the coating layer (31), coating layer (31) remaining By leaving a thicker coated area compared to the sections, the coating layer (31) opening area which serves to hold to facilitate peeling (63) 5 is the creation of.

8. This method complies with Claim 1 and its characteristic feature is that the coating process is applied after the coating process. The material (31) is cured using a drying machine (40).

9. This method complies with Claim 8 and its characteristic feature is that the drying process is done using UV, UV-LED, using at least one of the following technologies: infrared or hot air It is the realization of.

10. This method complies with Claim 1, and its characteristic is that the boxes are 15 after the curing process. (10) by passing through cooling machines (50) and cooling tunnel (51) It is cooling.

11. The method is in accordance with Claim 1 and its feature is the opening of the perforated line (62). Laser (61) parameters are precise according to film thickness and material structure. It is carried out by adjusting it in this way.

12. The method is in accordance with Claim 1 and its feature is; perforated line on the coating (62) instead of laser (61) the opening process is done by mechanical blade, punch mold or similar This is accomplished using a mechanical cutting system. 25 13. Lid (12) and side surface top area (11) of aluminum beverage cans (10) to ensure hygiene of parts that come into contact with the consumer's mouth (C) It is a system used for the purpose of; its feature is the cover (12) and the upper side surface. (11) in film form, a 30 that the consumer (C) can peel off by hand. characterized by a coating machine (30) that applies a coating layer (31). is being done. 14 14. A system that complies with claim 13, and its characteristic is the aforementioned coating layer. (31) a perforated line (62) on it to make it easy to peel off. It includes a perforated cutting machine (60) that opens.

15. A system in accordance with claim 13, the feature of which is; coating machine (30), a spray that enables the coating process to be carried out by spraying It includes the title (32).

16. A system in accordance with claim 13, the feature of which is; coating machine (30), 10 This allows the coating process to be carried out through direct contact with the surface. It includes a sponge cap (33).

17. A system conforming to Claim 13, characterized by its inline coating thickness. Measured by sensors and returned to the dosing pump with an accuracy of ±1 micron. It includes a sensor system that enables notification.

18. It is a system that complies with claim 13, and its feature is the opening of the perforated line (62). instead of laser (61) mechanical blade, punch die or similar mechanical It includes a perforated cutting machine (60) which performs the cutting with a cutting system. 20 19. A system that complies with claim 13, and its feature is; box (10) instead of label (21) leaving an uncoated area on the coating layer (31) It contains an auricle that forms an opening point.

20. A system compliant with Claim 13, characterized by its coating-on-coating properties. It includes a drying machine (40) that cures the material (31).

21. A system that complies with claim 20, and its feature is that the drying machine (40), UV, A 30 that uses at least one of the following technologies: UV-LED, infrared, or hot air. It includes drying technology.

22. A system that complies with Claim 13, and its feature is that the boxes after coating (10) a cooling machine (50) and cooling tunnel (51) that provides cooling It includes.

23. An aluminum beverage can (10) has the following features; the can (10) lid (12) 5 and hygiene on the upper part of the side surface (11), on the box (10) surface. a peelable film coating applied to provide It contains layer (31).

24. A box (10) conforming to claim 23, and its feature is; coating layer (31) 10 on which the coating can be easily peeled off by the consumer (C) It is characterized by containing a perforated line (62) which provides 25. A box (10) conforming to claim 23, whose characteristic is that the coating layer (31), an antimicrobial, transparent and peelable film layer on the surface of the box (10) 15 a water-based, solvent-based or UV-based material formulation It includes.