A clean-in-place system for volumetric filling machines and a method thereof

Abstract

The present invention provide a system (100) and method (500) for clean-in-place or CIP system (100) for volumetric filling machines, comprises a control unit; a plurality of sensors (110) configured to real-time monitoring of cleaning parameters; a plurality of valves (108) configured to direct the flow of product and cleaning agents through the volumetric filling machine; an adaptive flow mechanism (200) adapted to control the circulation of cleaning agents through a filling cylinder (102), includes: a straight section tube (212) for product filling; and a conical section tube (206) for cleaning. The system for volumetric filling machines is a specialized cleaning system configured to automatically and effectively clean the internal parts of the filling machine.

Description

[0001] A CLEAN-IN-PLACE SYSTEM FOR VOLUMETRIC FILLING MACHINES AND A METHOD THEREOF

[0002] FIELD OF THE INVENTION

[0003] Embodiments of the present invention generally relates to automated cleaning systems for enhancing the efficiency and effectiveness of cleaning processes of clean- in-place (CIP) system, more particularly, the present invention pertains to a clean-in- place system for volumetric filling machines and a method thereof.

[0004] BACKGROUND OF THE INVENTION

[0005] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of it being mentioned in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.

[0006] Conventional clean-in-place (CIP) systems in various industries, such as food and pharmaceuticals, primarily focus on automated cleaning of equipment. Such systems circulate cleaning and sanitizing agents to ensure hygiene and safety. Which are designed to clean interior surfaces of pipes, vessels, and machinery without dismantling, employing various types of cleaning fluids and methods.

[0007] Despite their utility, existing CIP systems often face issues like high energy and water consumption, extended cleaning times, and inefficient removal of contaminants. Inconsistent cleaning effectiveness and the inability to adapt to different types of equipment or contamination levels further compound these issues. These shortcomings result in increased operational costs and potential safety risks due to inadequate cleaning.

[0008] In traditional volumetric filling systems used in industries like food and beverage, the process involves two distinct phases: filling and washing. The filling phase utilizes a volumetric cylinder equipped with a piston disc, which is operated by a combination of motors and valves. This mechanism allows for precise control over the amount of product dispensed. However, the washing or cleaning phase is separate from the filling operation. Typically, cleaning agents are intermittently pumped through the filling apparatus, but this system is not integrated into the main production line. This separation leads to several inefficiencies. The washing efficiency is often suboptimal, requiring longer cleaning times and increased consumption of cleaning materials. Furthermore, the lack of integration necessitates additional manual cleaning efforts to ensure comprehensive sanitation of the filling group, complicating the overall process and potentially impacting production efficiency and hygiene standards.

[0009] Thus, there is a pressing need for an improved clean-in-place (CIP) system that addresses these shortcomings by introducing a more efficient, resource-conserving, and adaptable system. The present invention not only ensures higher safety standards but also contributes to environmental sustainability and operational cost reduction in industries relying on CIP systems.

[0010] SUMMARY OF THE INVENTION

[0011] According to an aspect of the present invention, a system for clean-in-place (CIP) system for volumetric filling machines, comprises a control unit; a plurality of sensors configured to real-time monitoring of cleaning parameters; a plurality of valves configured to direct the flow of product and cleaning agents through the filling cylinder; an adaptive flow mechanism adapted to control the circulation of cleaning agents through a filling cylinder, includes: a straight section tube for product filling; and a conical section tube for cleaning.

[0012] In accordance with an embodiment of the present invention, the adaptive flow mechanism includes a plurality of variable speed pumps and a plurality of valves, and is capable of connecting with an entire production line of the volumetric filling machines.

[0013] In accordance with an embodiment of the present invention, the cleaning parameters are predefined in the control unit based on the type of equipment and specific contamination levels, ensuring targeted cleaning. In accordance with an embodiment of the present invention, the plurality of sensors configured to monitor the levels of filing product and cleaning agents within the collection hopper and filling cylinder.

[0014] In accordance with an embodiment of the present invention, the system is configured to integrate the filling machine with the entire production line during the washing process, so that the entire production line may be washed.

[0015] In accordance with an embodiment of the present invention, the control unit includes a programmable logic controller or PLC for automating the filling and cleaning processes with real-time feedback from the sensors.

[0016] In accordance with an embodiment of the present invention, the system comprises a user interface for customizing cleaning cycles, allowing for adaptability to various equipment types and contamination levels.

[0017] In accordance with an embodiment of the present invention, the system further comprises an integrated feedback system, configured to adjust cleaning cycles based on real-time sensor inputs.

[0018] According to another aspect of the present invention, a method for cleaning volumetric filling machines using a clean-in-place or CIP system, the method comprises step of monitoring cleaning parameters via a plurality of sensors, utilizing an adaptive flow mechanism having a straight section tube and a conical section tube, controlling the flow of product and cleaning agents through the adaptive flow mechanism using a plurality of valves and a plurality of variable speed pumps, and employing a control unit to automate and optimize the filling and cleaning processes based on sensor feedback.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments. These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:

[0021] Fig. 1 illustrates an exemplary clean-in-place (CIP) system for volumetric filling machines, in accordance with an embodiment of the present invention;

[0022] Fig. 2 illustrates an exemplary adaptive flow mechanism, in accordance with an embodiment of the present invention;

[0023] Fig. 3 illustrates an exemplary volumetric filling machines configured with clean-in- place (CIP) system to perform a first path operation, in accordance with an embodiment of the present invention;

[0024] Fig. 4 illustrates an exemplary volumetric filling machines configured with clean-in- place (CIP) system to perform a second path operation, in accordance with an embodiment of the present invention; and

[0025] Fig. 5 illustrates a flowchart depicting the process steps of a method for cleaning volumetric filling machines using a clean-in-place (CIP) system.

[0026] DETAILED DESCRIPTION OF THE INVENTION

[0027] While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this description, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the like is included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.

[0028] In this disclosure, whenever a composition or an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element or group of elements with transitional phrases “consisting of”, “consisting”, “selected from the group of consisting of, “including”, or “is” preceding the recitation of the composition, element or group of elements and vice versa.

[0029] The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention. The present invention will now be described in detail with the help of accompanying drawings:

[0030] Volumetric filling machines are used in various industries for precise and consistent filling of containers with a set volume of liquid or semi-liquid products. They operate by measuring and dispensing a specific volume of product, making them ideal for packaging in sectors like food and beverage, pharmaceuticals, and cosmetics. These machines are valued for their accuracy, efficiency, and ability to handle products of various viscosities.

[0031] The present invention related to a Clean-In-Place (CIP) system for volumetric filling machines is a specialized cleaning system configured to automatically and effectively clean the internal parts of the filling machine. The CIP system may be capable of washing the filling machine equipments and entire production lines. The system circulates cleaning agents through the machine, targeting areas where product residue can accumulate. Proper cleaning is crucial in industries where hygiene and precision, like food and pharmaceuticals, are paramount. The CIP system ensures that the volumetric filling machines maintain consistent cleanliness standards without the need for manual disassembly of machine parts, and enhancing the efficiency of the cleaning process with minimum downtime .

[0032] Figure 1 illustrates an exemplary volumetric filling machine, in accordance with an embodiment of the present invention. As shown in the figure 1 , the system (100) comprises a product inlet line (1011 ), which is connected to a collection hopper (101 ). The hopper is capable of gathering the product that needs to be operated through the inlet line (1011 ). The choice of material for the Collection Hopper (101 ) depends on several important parameters and considerations, some of them are, but not limited to, cost, temperature, pressure, reactivity of environment, product, and cleaning agents. The material for the Collection Hopper (101 ) may be selected from, but not limited to, 304 or 316 stainless steel, polyethylene (HDPE) or polypropylene (PP), Glass, Aluminum and other Coated Materials such as non-stick coatings for easy cleaning. Further, the system (100) may be equipped with a plurality of valves (108a-108f) to regulate the flow of either the product or cleaning agent within the filling machine, depending on which is in use. Similarly, the choice of plurality of valves (108a-108f) depends the parameters such as but not limited to, type of fluids used in the system (100), range of flow rate and pressure of both product and cleaning agents required, operating temperature, fluid contamination, level of control requirement, maintenance, environmental conditions, fail-safe requirements, reliability, and compatibility with the system (100). The plurality of valves (108a-108f) may be selected from, but not limited to, Butterfly Valves, Ball Valves, Diaphragm Valves, Gate Valves, Solenoid Valves, Control Valves, Pressure Relief Valves, Three-Way and Four-Way Valves, Angle Valves, Pinch Valves or combination thereof.

[0033] Furthermore, the collection hopper (101 ) may be equipped with a plurality of sensors (110), strategically positioned to accurately measure levels or quality of the products or cleaning agents. Below the collection hopper is a filling cylinder (102) for accumulating the metric quantity of product required for filling. The metric quantity is modulated by a piston disc (104), located within the filling cylinder (102), which moves back and forth to draw product from the collection hopper and dispense it into the designated bag or container for filling or packing.

[0034] The products used in the volumetric filling machines may be selected from, but not limited to, Ketchup, mayonnaise, salad dressings, water, juice, soft drinks, alcoholic beverages, Milk, yogurt, dietary supplements, herbal extracts, Motor oils, lubricants, paints automotive fluids, pesticides, herbicides, fertilizers or syrups etc. The cleaning agents may be used in the Volumetric filling machines may be selected from, but not limited to, acid-based cleaners, citric acid, phosphoric acid, nitric acid-based cleaners, sodium hydroxide (NaOH), detergent-based cleaners, chlorine-based compounds, hydrogen peroxide, enzymatic cleaners and other specialized cleaners.

[0035] Figure 2 illustrates an exemplary adaptive flow mechanism (200), in accordance with an embodiment of the present invention. The adaptive flow mechanism (200) is an essential part of the clean-in-place (CIP) system and consists of two hollow sections: a straight section tube and a conical section tube. The straight section tube (212) comes fitted with a piston disc (204, 104) and functions as the filling cylinder in the volumetric filling machine, where the precise filling and dispensing of the product occurs. Whereas, the conical section tube (206) is designed to enhance the cleaning of the filling cylinder by expelling the contaminated cleaning agent from the system. Within the adaptive flow mechanism, the piston disc (104) moves back and forth along its length, transitioning between three designated limits: Q (0) or level (2600), Q-max or level (2611 ), and CIP-limit or level (2601 ). The product filing operation took place between Q (0) or level (2600) and Q-max or level (2611 ), and the washing operation took place between Q (0) or level (2600) and CIP-limit or level (2601 ). Further, the adaptive flow mechanism may be operationally connected to a product dispensing line (106) through V2 or valve 2 (108b).

[0036] Figure 3 and Figure 4 illustrate an exemplary volumetric filling machine configured with clean-in-place (CIP) system (100) by ensuring that each component receives focused and efficient cleaning. In accordance with an embodiment of the present invention, the cleaning agent is pumped to the filling machine via the inlet line (1011 ). The cleaning process begins by closing V3 or valve 3 (108c). Subsequently, V4 or valve 4 (108d), V5 or valve 5 (108e) and V6 or valve 6 (108f) are opened strategically, allowing the cleaning agent to flow into the collecting hopper (101 ), product inlet line (105), and pressure release line (107).

[0037] In an exemplary embodiment of the present invention, the influx of cleaning agents may be controlled by strategic manipulation of V4, V5, and V6. To wash the product inlet line, valve V4 is kept closed, while V5 is opened, and V6 remains closed. This configuration ensures that the cleaning agent is directed exclusively towards the product inlet line, enabling a thorough cleansing of any residue or buildup that may have occurred during the filling process.

[0038] For the purpose of washing the collection hopper (101 ), an alternate configuration is employed. Here, valve V4 is opened to allow the cleaning agent to flow into the hopper, while V5 and V6 are kept closed. This setup concentrates the flow of the cleaning agent directly into the hopper, effectively cleaning it from any contaminants or residues. Lastly, in order to clean the pressure release line, a third configuration is operated by opening both V4 and V6, while keeping V5 closed. The simultaneous opening of V4 and V6 facilitates a cleaning route to the pressure release line, ensuring that any blockages or accumulations are effectively removed.

[0039] During the cleaning of collection hopper (101 ), the level of the cleaning agent is continuously monitored by high and low limit sensors (1111 and 1100). When the high limit is reached, the influx of the cleaning agent from the inlet pipe (1011 ) is reduced by controlling the speed of the main pump (not shown in figures) of the production line.

[0040] For cleaning the remaining components of the volumetric filling machine, the cleaning agent is directed into two distinct paths. In the first path operation as shown in Figure 3, the piston disc (204) is positioned at the CIP-limit or level (2601 ), which facilitates the thorough cleaning of the filling cylinder. During first path operation, V1 or valve 1 (108a) is opened to direct the cleaning agent from the collection hopper (101 ) towards the straight section tube (212) of the adaptive flow mechanism, or the filling cylinder (102), for its cleaning. As the cleaning agent begins to fill the filling cylinder (102), the piston disc (104) moves from Q(0) or level (2600) to the CIP-limit or level (2601 ), located at the conical section tube (206) of the adaptive flow mechanism, creating an opening for the release of the contaminated cleaning agent. This contaminated agent is then collected in the collecting tank (210) and subsequently expelled from the system via a return line (1010).

[0041] On the other hand, during second path operation as shown in figure 4, the piston disc is repositioned to the Q (0) or level (2600), enabling the cleaning agent to be directed through the product dispensing line (106). As the piston disc reaches at Q (0) or level (2600), V2 or valve 2 (108a) is opened to direct the cleaning agent from collection hopper (101 ) towards the product dispensing line. The cleaning agent passes through the piston disc surface and entire dispensing line to effectively clean them from any contaminants or residues. Further, the contaminated agent is then collected in the collecting tank (210) and subsequently expelled from the system via a return line (1010). The above embodiment optimizes the cleaning process within the volumetric filling machine by ensuring that each component receives focused and efficient cleaning, such as the product inlet line, the collection hopper, the pressure release inlet, filling cylinder, piston disc surface, product dispensing line and tap. The selective operation of valves V1 , V2, V3, V4, V5, V6 and piston disc under different scenarios exemplifies the adaptability and effectiveness of the CIP system in maintaining the hygiene and functionality of the volumetric filling machine.

[0042] The automated opening and closing of the valves (108a-108f) are controlled by a control unit to ensure a cyclical changeover between the first and second flow paths. This first path remains active for a preset duration (e.g., one minute) based on optimal cleaning parameters before switching the second path again which also remains active for a preset duration (e.g., one minute). This changeover may take place number of times in a single cleaning process to ensure effective cleaning of all the components of the filling machine.

[0043] The conical section tube (204) with its angled walls and varying diameter along the length allows cleaning fluids to establish vortex flows and swirling motions which results in improved overall scrubbing efficiency in comparison to convention fill length standard straight tube configurations.

[0044] In an exemplary embodiment of the present invention, the system (100) may further include one or more sensors (1101 ) selected from, but not limited to, temperature sensors, pressure sensors, flow sensors, Ph -sensors or combination thereof. These sensors are configured to real-time monitoring of cleaning parameters of the filling machine based on the type of equipment and specific contamination levels, ensuring targeted cleaning. The cleaning parameters are predefined and selected from, but not limited to, PH value of the product, pressure and flow rate of product through connection pipes. If the monitored value of cleaning parameters cross the threshold values defined by the operator or manufacturer of the filing machine, the sensor communicates to the control unit to start the cleaning process to clean the machine. The control unit automatically controls the operation of speed varying pumps and the plurality of valves based on the sensor data. In accordance with an embodiment of the present invention, the control unit may include one or more Programmable Logic Controllers (PLCs). The selection of the one or more Programmable Logic Controllers (PLCs) may be based on, but not limited to, Processing Speed, I / O Capacity, Network Capabilities, Memory and Storage, Environmental Resistance, Expansion Options, Software Compatibility, Reliability and Support. The one or more Programmable Logic Controllers (PLCs) may be selected from, but not limited to, Siemens SIMATIC S7 Series, Allen-Bradley ControlLogix, Mitsubishi Electric FX Series, Omron Sysmac Series or Schneider Electric Modicon Series.

[0045] In some embodiments, the system (100) may include a user Interface connected to the one or more Programmable Logic Controllers (PLCs). It may further include, but not limited to Display Screen, touch enabled display, one or more speakers, one or more LEDs. It may display graphics to interact with the system (100) displaying, but not limited, Status Indicators, starting / stopping cycles, adjusting settings, regular maintenance, data for analysis and optimization or flag issues set thresholds for temperature, pressure, etc. navigating menus, prominent button for immediate system shutdown or combination thereof.

[0046] The display may be, but not limited to, Light-emitting diode display or LED, electroluminescent display or ELD, liquid crystal display or LCD, Organic light-emitting diode or OLED & AMOLED display. Furthermore, the user interface (not shown) may include accessories like key based input unit, or one or more switches, or pointing devices like a mouse etc. envisaged to provide input capability to enable a user to enter his / her details.

[0047] In some embodiment, the user interface may be a touch input-based display that integrates the input-output functionalities. In an additional or alternative embodiment, the control unit may be part of a computing device operated by a user or may be connected with the computing devices such as desktop PC, laptop, PDA or hand-held computing device such as smartphones and tablets. This enables the user to remotely operate the system (100) and further automate its operation. In some embodiments, the system (100) may also include a data repository (not shown). The data repository may be a local storage such as SSD, eMMC, Flash, SD card, etc. In any manner, the data repository is envisaged to be capable of providing the data to the control unit, when the data is queried appropriately using applicable security and other data transfer protocols. The memory unit may store, but not limited to, images, videos, audios, one or more algorithms, data from sensors, and instructions related to the aquarium, maintenance schedules and data related to the optimum parameters required to be maintained in the system (100).

[0048] In some embodiments, the system (100) may also include one or more communication modules (not shown) are configured to establish a communication network (not shown). The communication network may be used to connect the components within the system (100) itself, or to connect the system (100) with servers of the concerned authorities (such as police, municipal corporations, hospitals, fire stations etc.). In that sense, the communication network can be a short-range communication network and / or a long-range communication network, wired or wireless communication network selected from one of, but not limited to, Bluetooth, radio frequency, WIFI network or satellite communication network providing maximum coverage. Additionally, a communication interface may include, but not limited to, a serial communication interface, a parallel communication interface or a combination thereof. The communication network (not shown in figures) may be implemented using a number of protocols, such as but not limited to, TCP / IP, 3GPP, 3GPP2, LTE, IEEE 802.x etc.

[0049] In accordance with an embodiment of the present invention, the Clean-In-Place (CIP) system includes an integrated feedback system that continuously monitors and adjusts the cleaning process. Sensors measure various cleaning parameters such as the flow rate of cleaning agents, temperature, and pressure, ensuring the cleaning process is efficient and thorough. The measured data is then feeded to the feedback system which accordingly adjust valves and other components in real-time, optimizing the cleaning cycle and reducing cleaning time. This integration enhances the overall efficiency and effectiveness of the CIP system, ensuring the volumetric filling machine maintains optimal hygiene and performance standards. Figure 5 illustrates a flowchart depicting the process steps of a method (500) for cleaning volumetric filling machines using a clean-in-place (CIP) system (100). The figure 5 provides an overview flowchart (500) of the complete cleaning method using the automated CIP system (100). It depicts the key steps like - monitoring sensors to control filling and cleaning agent levels in the hopper, utilizing the adaptive flow mechanism (200) to switch between straight and conical tube configurations, controlling valves / pumps to facilitate the first and second path cleaning operations described earlier, and finally employing the control unit to automate and optimize the entire washing method.

[0050] A detailed explanation of Figure 5 is as follows:

[0051] Step 1 (502) - Monitor Cleaning Parameters:

[0052] The first step involves monitoring various cleaning parameters via the strategically placed sensors (1101 ). Key parameters checked in real-time are those which impact the quality of the product in operation such as concentrations of impurities, temperature, pressure and flow rate to ascertain system (100) conditions.

[0053] Step 2 (504) - Utilize Adaptive Flow Mechanism:

[0054] This step configures the suitable flow path by utilizing a plurality of valves and adaptive flow mechanism (200) having both straight (212) and conical (206) tube sections. Selection happens based on whether first path or second path cleaning is intended based on the stage in the wash cycle.

[0055] Step 3 (506) - Control Flow Using Valves & Pumps:

[0056] Precise control over opening / closing of valves (108) and speed of the variable pumps (202) ensures optimal direction and flow rate of cleaning agents ensures that all the components of the filling machine get cleaned. This optimization happens continuously through the cycle via a control unit.

[0057] Step 4 (508) - Employ Control Unit: The automated control unit ties the entire method together by analyzing sensor measurements to determine cleaning progress and make decisions around adapting pump speeds or valve positions accordingly to maximize efficiency. The end outcome is properly cleaned equipment.

[0058] It begins with the Programmable Logic Controller (PLC) initiating the cycle. Sensors (1101 ) across the system (100) monitor real-time parameters like impurities concentration, PH value, temperature, pressure, and flow rates, feeding this information to the PLC. The PLC then controls pumps and various valves (108a-108f), managing the flow of cleaning agents into the filling machine. By strategically opening and closing of the valves, the cleaning agent is passed through various components of the filling machine. The adaptive flow mechanism (200), consisting of a straight section tube (106) and a conical section tube (104), facilitates efficient cleaning of the filling cylinder and by altering flow paths, the piston disc and product dispensing line is also get cleaned. Variable speed pumps (202) are regulated to maintain optimal cleaning agent pressure and flow rates. During this process, the system’s (100) status is displayed on the user interface, allowing for monitoring and adjustments. Once the cleaning is complete, the PLC ensures the system (100) is adequately rinsed with clean water and resets for the next operation. This orchestrated sequence ensures effective cleaning with minimal manual intervention.

[0059] In the event of an emergency or system (100) anomaly, the Clean-In-Place (CIP) system (100) for volumetric filling machines is equipped with a robust safety mechanism. The Programmable Logic Controller (PLC), constantly receiving data from various sensors (110), is programmed to detect any irregularities, such as extreme pressure, temperature spikes, or mechanical failures. Upon detecting such anomalies, the PLC immediately triggers an emergency shutdown protocol. This rapid response halts all ongoing operations, effectively minimizing potential damage or hazards. Simultaneously, the system (100) generates alerts, notifying operators of the specific issue through the user interface. This immediate shutdown and alert mechanism are crucial for ensuring safety and preventing extensive damage to the system (100) or the product. In the CIP system (100), data logging and analysis for maintenance are conducted through a systematic approach. Sensors (110) within the system (100) constantly gather key operational data, such as temperature, pressure, flow rates and level of product or cleaning agent. This data is then stored in a centralized database, accessible for analysis. Specialized software processes this data, detecting patterns and predicting potential system (100) issues, facilitating preemptive maintenance actions. The system (100) also generates maintenance alerts based on this analysis, ensuring timely servicing. Regular performance reports drawn from this data help in maintaining optimal system (100) efficiency and longevity.

[0060] The Clean-In-Place or CIP system (100) for volumetric filling machines is a highly advanced and automated system (100) which increases the effectiveness of cleaning process. The core of this system (100) is the Programmable Logic Controller (PLC), which intelligently manages the operation based on inputs or feedback from a network of sensors (110). These sensors continuously monitor critical parameters like temperature, pressure, and flow rates. The system (100) employs a series of valves (108a-108f) to regulate the flow of cleaning agents within the entire filling machine, and its design includes an adaptive flow mechanism featuring straight (212) and conical tubes (206). This mechanism is key to ensuring effective cleaning, with variable speed pumps (202) maintaining ideal pressure and flow. The user interface of the system (100) allows operators to monitor and adjust settings in real-time. Safety is a paramount feature; the PLC is programmed to initiate an emergency shutdown and send alerts in case of anomalies. The system (100) also includes comprehensive data logging capabilities for maintenance, which facilitate predictive analysis and timely servicing. The dual-path approach illustrates the system's perfect balance between operational efficiency and strict adherence to cleanliness and safety protocols.

[0061] The Clean-In-Place (CIP) system (100) for volumetric filling machines offers several benefits:

[0062] • Enhanced Cleaning Efficiency: The adaptive flow mechanism with different tube sections (straight and conical) specifically designed for product filling and cleaning provides an efficient cleaning process, reducing downtime and increasing productivity. • Real-Time Monitoring and Control: The integration of a plurality of sensors for realtime monitoring of cleaning parameters ensures the cleaning process is constantly optimized according to the specific needs of the system, leading to a more effective and thorough cleaning.

[0063] • Automated Process Control: The inclusion of a programmable logic controller (PLC) in the control unit automates the filling and cleaning processes, reducing the need for manual intervention and minimizing human error.

[0064] • Adaptability to Different Contamination Levels: The system's ability to predefine cleaning parameters based on equipment type and contamination level ensures a targeted cleaning approach, enhancing the effectiveness of the cleaning process for different situations.

[0065] • Customization through User Interface: The provision of a user interface for customizing cleaning cycles allows users to adapt the system to various equipment types and contamination levels, offering versatility and broader applicability.

[0066] • Integration with Production Line: The system's capability to connect with an entire production line of volumetric filling machines enhances its utility in large-scale production environments, streamlining the cleaning process across multiple machines.

[0067] • Variable Speed Pumps for Precise Control: The use of variable speed pumps in conjunction with valves allows for precise control of the flow of product and cleaning agents, leading to more effective cleaning and reduced waste.

[0068] • Feedback-Driven Cleaning Cycles: The integrated feedback system that adjusts cleaning cycles based on real-time sensor inputs ensures that the cleaning process is continuously optimized for the best results.

[0069] • Reduction in Cleaning Time and Labor Costs: By automating and optimizing the cleaning process, the system potentially reduces the time and labor costs associated with manual cleaning procedures.

[0070] • Enhanced Product Safety and Compliance: By ensuring thorough and consistent cleaning, the system helps maintain high hygiene standards, which is crucial in industries where product safety and regulatory compliance are of paramount importance, such as in food and beverage or pharmaceutical manufacturing.

[0071] • Previous packaging machines can be modified to the new design. • The present invention supports the process of preserving the environment by saving on cleaning materials and reducing water consumption.

[0072] • It is useful in prolonging the number of working hours of the packing group because there is no need for the daily disassembly and assembly process after the completion of each packing process.

[0073] It should also be understood that, unless specifically stated otherwise as apparent from the following discussion, it is appreciated that throughout the description, discussions utilizing terms such as "controlling" or "obtaining" or "computing" or "storing" or "receiving" or "determining" or the like, refer to the action and processes of a computer system, or similar electronic computing device, that processes and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.

[0074] Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.

Claims

Claims:

1. A clean-in-place or CIP system (100) for volumetric filling machines, comprising: a control unit; a plurality of sensors (110) configured to real-time monitoring of cleaning parameters; a plurality of valves (108a-f) configured to strategically direct the flow of cleaning agent within the volumetric filling machine; an adaptive flow mechanism (200) adapted to control the circulation of the cleaning agent through a filling cylinder (102), includes: a straight section tube (212) for product filling; and a conical section tube (206) for cleaning.

2. The system (100) of claim 1 , wherein the plurality of valves (108a-f) controls the flow of cleaning agent within the volumetric filling machine to clean entire components of the filling machine.

3. The system (100) of claim 1 , wherein the CIP system is operatively connected with a production line of the product and configured to clean the entire production line.

4. The system (100) of claim 1 , wherein the cleaning parameters are predefined in the control unit based on the type of equipment and specific contamination levels, ensuring targeted cleaning.

5. The system (100) of claim 1 , wherein the plurality of sensors (110) configured to monitor the levels of filling product and cleaning agents within the filling machine.

6. The system (100) of claim 1 , wherein the control unit includes a programmable logic controller (PLC) for automating the filling and cleaning processes with real-time feedback from sensors.

7. The system (100) of claim 1 , further comprising a user interface for customizing cleaning cycles, allowing for adaptability to various equipment types and contamination levels.

8. The system (100) of claim 1 , further comprising an integrated feedback system, configured to adjust cleaning cycles based on real-time sensor inputs.

9. A method (500) for cleaning volumetric filling machines using a clean-in- place (CIP) system (100), the method (500) comprising: monitoring (502) cleaning parameters via a plurality of sensors (110); utilizing (504) an adaptive flow mechanism (200) having a straight section tube (212) and a conical section tube (206); controlling (506) the flow of product and cleaning agents through the adaptive flow mechanism using a plurality of valves (108a-f) and a plurality of variable speed pumps; and employing (508) a control unit to automate and optimize the filling and cleaning processes based on sensor feedback.

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