System for monitoring integrity of a bellow in an aseptic capping machine

Abstract

The present disclosure provides a system (1) for monitoring the integrity of a bellows (2) within a capping device (10) for capping containers. The capping device (10) comprises a capping head (101) vertically movable inside a first environment (OE) for capping a container (B) positioned in a second environment (PE) with a cap (W). The bellows (2) separates the second environment (PE) from the first environment (OE) and is integral with the vertical movement of the capping head (101). The bellows (2) can adopt a not pressurized condition and a pressurized condition. The system (1) includes a pressurization system (5) for internally pressurizing the bellows (2) to adopt the pressurized condition, and a sensor (3) for detecting the quality of air in the second environment (PE) while the bellows (2) adopts the pressurized condition.

Description

[0001] SYSTEM FOR MONITORING INTEGRITY OF A BELLOW IN AN ASEPTIC CAPPING MACHINE FIELD OF INVENTION

[0002] The present disclosure relates to monitoring systems for capping devices, and more particularly to a system for monitoring the integrity of a bellow in an aseptic capping machine.

[0003] BACKGROUND

[0004] Capping devices are widely used in the packaging industry to seal containers with caps. These devices play a crucial role in maintaining product integrity, especially in industries where product sterility is paramount, such as food and beverage, pharmaceuticals, and cosmetics. In many applications, capping devices operate in environments where cleanliness is of utmost importance, necessitating the separation of the capping mechanism from the product environment.

[0005] Bellows are often employed in capping devices to provide a flexible barrier between different environments within the machine. These bellows allow for the vertical movement of capping heads while maintaining separation between clean and potentially contaminated areas. The integrity of these bellows is essential for preserving the cleanliness of the product environment and ensuring the quality of the packaged goods.

[0006] Monitoring the condition of bellows in capping devices presents several challenges. The dynamic nature of the capping process, involving repeated vertical movements, can lead to wear and tear on the bellow material over time. Additionally, the enclosed nature of many capping machines makes visual inspection of bellows difficult without disrupting production. Furthermore, subtle damages or small perforations in the bellow may not be immediately apparent, potentially compromising the sterility of the production environment before being detected.

[0007] Traditional methods of bellow inspection often rely on periodic visual checks or scheduled replacements, which may not adequately address sudden failures or gradual degradation. These approaches can lead to unnecessary downtime for inspections or, conversely, may not detect issues quickly enough to prevent contamination events. Moreover, the increasing demand for continuous production and higher throughput in packaging lines makes frequent manual inspections impractical and costly.

[0008] It has been appreciated that a system is needed that overcomes one or more of these problems.

[0009] SUMMARY

[0010] In a first aspect, a system for monitoring the integrity of a bellow within a capping device for capping containers is provided. The system includes a capping device comprising a capping head which is at least vertically movable inside a first environment for capping a container being positioned in a second environment by means of a cap, the device comprising also said bellow, which separates said second environment from said first environment and which is integral with the vertical movement of the capping head. The bellow can adopt a not pressurized condition in which the bellow is not internally pressurized, and a pressurized condition inwhich the bellow is internally pressurized by means of a gas which is for example air. The system further includes a pressurization system for internally pressurizing the bellow so that the bellow adopts said pressurized condition, and a sensor for detecting the quality of air in said second environment.

[0011] This system is designed to make a reliable assessment about the integrity of the bellow, which is a critical component for maintaining cleanliness in the second environment where the capping operation occurs. If there is a rupture or damage in the bellow, it will cause air to pass through the bellow from the first environment to the second environment, potentially lowering the air quality in the second environment. The sensor can detect this change, thereby assessing the mechanical integrity of the bellow. The internal pressurization of the bellow enhances the monitoring capability by increasing the volume of air that would flow through any damage or rupture, providing a more accurate assessment of the bellow's integrity.

[0012] The containers may be configured for containing various types of pourable products. For example, the containers may contain carbonated liquids such as sparkling water, soft drinks, or beer. Alternatively, the containers may contain non-carbonated liquids including still water, juices, teas, sports drinks, wine, or milk. The containers may also be suitable for containing emulsions, sauces, or beverages containing pulps. In some examples, the containers may contain high acid food products or low acid food products. The containers B may additionally be suitable for containing products for home or personal care.

[0013] The containers may take various forms, such as bottles. For instance, the containers may be glass bottles or PET bottles. In other examples, the containers may be kegs, cans, or jars.

[0014] The monitoring system may further include an automatic control device for checking said integrity based on the detected quality, the sensor being configured for detecting the quality of air in said second environment while the bellow adopts the pressurized condition.

[0015] This automatic control device allows for rapid assessment of the bellow's integrity, enhancing the efficiency of the monitoring process.

[0016] The control device may be configured for making the bellow automatically adopt said pressurized condition, by means of said pressurization system, and may be configured so that said at least one control unit checks said integrity while the bellow adopts said pressurized condition.

[0017] This configuration ensures that the integrity check is performed under optimal conditions, with the bellow in its pressurized state, thereby increasing the reliability of the monitoring system.

[0018] The monitoring system may comprise an actuator for vertically moving the capping head, so that the extension of the bellow can vary as a function of the vertical position of the capping head. The control device may be configured for making the bellow automatically adopt an at least partially extended condition in which the bellow is at least partially extended, by means of said actuator, and may be configured so that said at least one control unit checks said integrity while the bellow adopts said at least partially extended condition and said pressurized condition.

[0019] The extension of the bellow results in a greater volume of air flowing through it if damage or rupture occurs, as the size of any opening created by damage or rupture will be enlarged by the extended condition adoptedby the bellow. This increased airflow leads to a more precise evaluation of the bellow's actual integrity, further enhancing the reliability of the monitoring system.

[0020] In a second aspect, a capping device for capping containers is provided. The capping device includes a monitoring system according to the first aspect and said capping head.

[0021] This integration of the monitoring system into the capping device allows for continuous monitoring of the bellow's integrity during the capping process, ensuring consistent production quality.

[0022] The capping device may be an aseptic or ultraclean capping device, the second environment may be a protected environment which is aseptic or ultraclean, and the first environment may be not aseptic and not ultraclean. In the case of an ultraclean or aseptic capping device, where the second environment must be protected to maintain an ultraclean or aseptic state, the significance of the bellow is further amplified. Consequently, the monitoring system plays a vital role in ensuring that the quality of aseptic or ultraclean production is upheld and optimized.

[0023] In a third aspect, a packaging apparatus for packaging a pourable product by means of containers is provided. The packaging apparatus includes a capping device according to the second aspect.

[0024] This integration of the monitored capping device into a packaging apparatus ensures that the integrity of the packaging process is maintained throughout, from capping to final packaging, thereby enhancing overall product quality and safety.

[0025] BRIEF DESCRIPTION OF FIGURES

[0026] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0027] FIG. 1 illustrates a schematic view of a capping device with a monitoring system and operating in a production mode, according to aspects of the present disclosure.

[0028] FIG. 2 depicts a schematic view of the capping device of FIG. 1 with an extended bellow configuration, according to an embodiment.

[0029] FIG. 3 shows a schematic view of the capping device of FIG. 1 in a check mode, according to aspects of the present disclosure.

[0030] DETAILED DESCRIPTION

[0031] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein. The packaging apparatus includes a capping device (10) for packaging a pourable product using containers. A capping device (10) includes a capping head (101) for capping containers by means of caps. The caps can be for example screw caps or crown caps or push pull caps. Figures 1 and 2 refers to a case in which container (B) is capped by the capping device (10) by means of a cap (W). The capping device (10) also includes a monitoring system (1) for monitoring the integrity of a bellow (2) within the capping device (10). The bellow(2) separates a second environment (PE), where the container (B) being capped is positioned, from a first environment (OE).

[0032] FIG.3 illustrates a schematic view of the capping device (10) comprising the monitoring system (1). The monitoring system (1) is designed to maintain and verify the integrity of the bellow (2), which is a component that separates different environments within the capping device (10).

[0033] The containers (B) may be configured for containing various types of pourable products. For example, the containers (B) may contain carbonated liquids such as sparkling water, soft drinks, or beer. Alternatively, the containers (B) may contain non-carbonated liquids including still water, juices, teas, sports drinks, wine, or milk.

[0034] The containers (B) may also be suitable for containing emulsions, sauces, or beverages containing pulps. In some examples, the containers (B) may contain high acid food products or low acid food products. The containers (B) may additionally be suitable for containing products for home or personal care.

[0035] The containers (B) may take various forms, such as bottles. For instance, the containers B may be glass bottles or PET bottles. In other examples, the containers B may be kegs, cans, or jars.

[0036] The monitoring system (1) comprises several main components that work together to ensure the proper functioning of the bellow (2). These components include a pressurization system (5) for internally pressurizing the bellow (2), a quality sensor (3) for detecting air quality in the second environment (PE) where containers are capped, and a control device (4) for managing the monitoring process.

[0037] The capping head (101) of the capping device (10) is configured for vertical movement, as indicated by directional arrow V in FIGS. 1 and 2, at least to apply the cap W on the container B. The bellow (2) extends between the first environment OE and the second environment PE, and is designed to accommodate the vertical movement of the capping head (101) while maintaining separation between these environments.

[0038] Each of the Figures illustrates a schematic view of the capping device (10) comprising the monitoring system (1). The bellow (2) can adopt different conditions based on its internal pressure. A pressurization system (5) is provided for internally pressurizing the bellow (2). The pressurization system (5) comprises a pressure source (51) and a pressure line (52) connecting the pressure source (51) to the internal volume of the bellow (2). In some examples, the pressure source (51) may be a compressor.

[0039] The bellow (2) can adopt a not pressurized condition in which the bellow (2) is not internally pressurized, and a pressurized condition in which the bellow (2) is internally pressurized by means of a gas, such as air. The pressurization system (5) enables the bellow (2) to transition between these conditions as needed.

[0040] The monitoring system (1) also includes a quality sensor (3) for detecting the quality of air in the second environment (PE). The quality sensor (3) may be configured to detect various characteristics of the air in the second environment (PE). For example, the quality sensor (3) may be capable of detecting particles, humidity, or microorganisms in the air. This capability allows the monitoring system (1) to assess the integrity of the bellow (2) by monitoring changes in air quality that may result from any compromise in the bellow's structure.The monitoring system (1) includes a control device (4) for automatically checking the integrity of the bellow (2) based on the detected air quality. The quality sensor (3) is provided for detecting the quality of air in the second environment (PE). The control device (4) interfaces with the quality sensor (3) and a pressurization system (5) to manage the monitoring process.

[0041] FIG.3 illustrates the arrangement of the control device (4) within the monitoring system (1). The control device (4) comprises at least one control unit (41) for processing the data received from the quality sensor (3) and controlling the operation of the pressurization system (5).

[0042] The control device (4) is configured to automatically control the detection activity of the quality sensor (3). In some examples, the monitoring system (1) can operate in a periodic check mode, where the control device (4) initiates integrity checks at set intervals. Alternatively, the monitoring system (1) can operate in a continuous monitoring mode during production, allowing for real-time integrity assessment.

[0043] The quality sensor (3) is configured to detect air quality while the bellow (2) is in the pressurized condition. The control device (4) is programmed to check the integrity of the bellow (2) while the bellow (2) is in this pressurized condition. To achieve this, the control device (4) is configured to automatically make the bellow (2) adopt the pressurized condition using the pressurization system (5).

[0044] In some examples, the quality sensor (3) may be part of the automatic control device (4), allowing for seamless integration of sensor data into the control process. In other examples, the quality sensor (3) may be manual, allowing an operator to control the detection activity. In such cases, the control device (4) still includes at least one automatic control unit (41) for checking the integrity based on the manually detected quality.

[0045] The control device (4) may include additional features to enhance its functionality. For example, the control device (4) may incorporate an alarm system for alerting operators when the detected air quality falls below a predetermined threshold. Additionally, the control device (4) may include a display for showing the detected air quality, providing visual feedback to operators.

[0046] By integrating these various components and functionalities, the control device (4) enables comprehensive monitoring and management of the bellow's integrity, contributing to the overall efficiency and reliability of the capping device (10).

[0047] The monitoring system (1) includes an actuator (7) for vertically moving a capping head (101). The actuator (7) enables the vertical movement of the capping head (101), which in turn affects the extension of a bellow (2). As the capping head (101) moves vertically, the bellow (2) extends or contracts accordingly.

[0048] A control device (4) is configured to make the bellow (2) adopt an at least partially extended condition using the actuator (7). The control device (4) can command the actuator (7) to move the capping head (101) to various vertical positions, resulting in different degrees of bellow extension.

[0049] The control device (4) is programmed to check the integrity of the bellow (2) while the bellow (2) is in the at least partially extended condition. This integrity check can be performed at various stages of bellow extension, including a condition where the bellow (2) is completely extended.FIG.3 illustrates the arrangement of the actuator (7) in relation to the capping head (101) and the bellow (2). The actuator (7) is shown connected to the capping head (101), enabling its vertical movement as indicated by the directional arrow V.

[0050] The capping device (10) operates in different modes. In a production mode, the actuator (7) vertically moves the capping head (101) for capping containers. In a check mode, the control device (4) checks the integrity of the bellow (2) when the capping device (10) is not capping any container.

[0051] During the check mode, the control device (4) may command the actuator (7) to move the capping head (101) to specific positions, allowing for integrity checks at various bellow extensions. This process enables comprehensive assessment of the bellow's integrity across its full range of motion.

[0052] The ability to check bellow integrity in different extended conditions enhances the monitoring capabilities of the system. By examining the bellow (2) in various states of extension, from partially extended to fully extended, the control device (4) can detect potential issues that may only manifest under specific conditions.

[0053] The monitoring system (1) may be implemented in a capping device (10) that operates in aseptic or ultraclean conditions. In such implementations, the capping device (10) is configured to maintain a sterile or highly controlled environment during the capping process.

[0054] The second environment (PE) represents a protected environment that is maintained in an aseptic or ultraclean state. The first environment (OE), in contrast, is not maintained in an aseptic or ultraclean condition.

[0055] The bellow (2) serves as a barrier between the first environment (OE) and the second environment (PE). The integrity of the bellow (2) is particularly important in aseptic or ultraclean applications, as any breach in the bellow (2) may compromise the sterility or cleanliness of the second environment (PE).

[0056] The monitoring system (1) may play a role in maintaining the aseptic or ultraclean conditions of the second environment (PE) also by continuously assessing the integrity of the bellow (2). The quality sensor (3) detects changes in air quality within the second environment (PE), which may indicate a breach in the bellow (2). In aseptic or ultraclean applications, the control device (4) may be programmed with more stringent thresholds for air quality detection. This allows for rapid identification of even minor breaches in the bellow (2) that could potentially compromise the sterility or cleanliness of the second environment (PE).

[0057] The pressurization system (5) may be used to create a positive pressure differential between the bellow (2) and the second environment (PE) in aseptic or ultraclean applications.

[0058] By implementing the monitoring system (1) in aseptic or ultraclean capping devices (10), manufacturers can ensure consistent maintenance of sterile or highly controlled conditions during the capping process. This contributes to the overall quality and safety of the packaged products.

[0059] FIG.3 illustrates a schematic view of a capping device (10) comprising a monitoring system (1). The capping device (10) includes a capping head (101) for capping containers. The capping device (10) also includes abellow (2) and a barrier (6) that separate the second environment (PE) from the first environment (OE) within the capping device (10).

[0060] The bellow (2) and the barrier (6) are spatially interposed between the first environment (OE) and the second environment (PE). The bellow (2) and the barrier (6) delimit each of the first environment (OE) and the second environment (PE), maintaining separation between these environments while allowing for the vertical movement of the capping head (101).

[0061] The barrier (6) is a structural component to which the bellow (2) is attached. The bellow (2) follows the vertical movement of the capping head (101), allowing for flexibility in the separation between the environments. The attachment of the bellow (2) to the barrier (6) ensures that the integrity of the environmental separation is maintained during the operation of the capping device (10).

[0062] The capping device (10) operates in different modes. In a production mode, the capping device (10) performs capping operations on containers. In this mode, the capping head (101) moves vertically to apply caps to containers positioned in the second environment (PE).

[0063] In a check mode, the capping device (10) is not actively capping containers. During this mode, the monitoring system (1) performs integrity checks on the bellow (2). The control device (4) may command the actuator (7) to move the capping head (101) to specific positions, allowing for comprehensive assessment of the bellow's integrity across various states of extension.

[0064] The integration of the monitoring system (1) into the capping device (10) allows for continuous monitoring of the bellow's integrity during both production and check modes. This integration enhances the overall reliability and efficiency of the capping process while maintaining the necessary separation between the first environment (OE) and the second environment (PE).

[0065] A packaging apparatus for packaging a pourable product using containers may include a capping device (10). The capping device (10) comprises a monitoring system (1) for monitoring the integrity of a bellow (2) within the capping device (10).

[0066] The packaging apparatus may be configured to perform various operations related to packaging pourable products. These operations may include filling containers with the pourable product, capping the filled containers, and potentially other processes such as sterilization or labeling.

[0067] The capping device (10) with its integrated monitoring system (1) can be incorporated into the packaging apparatus as a component responsible for capping the filled containers. The monitoring system (1) enhances the reliability of the capping process by continuously assessing the integrity of the bellow (2), which separates different environments within the capping device (10).

[0068] In examples where the packaging apparatus operates in aseptic or ultraclean conditions, the incorporation of the capping device (10) with the monitoring system (1) may contribute to maintaining the required level of cleanliness or sterility throughout the packaging process. The monitoring system (1) helps ensure that the integrity of the bellow (2) is maintained, thereby preserving the separation between the protected environment where containers are capped and the external environment.The packaging apparatus may be designed to accommodate the vertical movement of the capping head (101) within the capping device (10). This design consideration allows for smooth integration of the capping device (10) into the overall packaging process, enabling efficient capping operations while maintaining the functionality of the monitoring system (1).

[0069] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

CLAIMS1. System (1) for monitoring the integrity of a bellow (2) within a capping device (10) for capping containers, the device (10) comprising a capping head (101) which is at least vertically movable inside a first environment (OE) for capping a container (B) being positioned in a second environment (PE) by means of a cap (W), the device (10) comprising also said bellow (2), which separates said second environment (PE) from said first environment (OE) and which is integral with the vertical movement (V) of the capping head (101) wherein:the bellow (2) can adopt a first condition, and a pressurized condition in which the bellow (2) is internally more pressurized than in said first condition, by means of a gas (A) which is for example air, the first condition being preferably a not pressurized condition of the bellow (2);a pressurization system (5) for internally pressurizing the bellow (2) so that the bellow adopts said pressurized condition;a sensor (3) for detecting the quality of air in said second environment (PE).

2. Monitoring system (1) according to Claim 1, wherein the monitoring system (1) comprises an automatic control device (4) for checking said integrity based on the detected quality of air, the control device (4) comprising at least one automatic control unit (41) for automatically checking said integrity based on the detected quality, the sensor (3) being configured for detecting the quality of air in said second environment (PE) while the bellow (2) adopts the pressurized condition.3.Monitoring system (1) according to Claim 2, wherein the control device (4) is configured for making the bellow (2) to automatically adopt said pressurized condition, by means of said pressurization system (5), and is configured so that said at least one control unit (41) checks said integrity while the bellow (2) adopts said pressurized condition.

4. Monitoring System (1) according to Claim 2 or 3, wherein the sensor (3) is part of the automatic control device (4), so that the detection activity of said sensor (3) is automatically controlled by said control device (4).

5. Monitoring System (1) according to Claim 2 or 3, wherein the sensor (3) is manual so that the detection activity of said sensor (3) can be manually controlled by an operator.

6. Monitoring system (1) according to any one or more of Claims 4 or 5, wherein the monitoring system (1) comprises an actuator (7) for vertically moving the capping head (101), so that the extension of the bellow (2) can vary as a function of the vertical position of the capping head (101), and the control device (4) is configured for making the bellow (2) to automatically adopt an at least partially extended condition in which the bellow (2) is at least partially extended, by means of said actuator (7), and is configured so that said at least one control unit (41) checks said integrity while the bellow (2) adopts said at least partially extendedcondition, and preferably while the bellow (2) adopts said pressurized condition and said at least partially extended condition.

7. Monitoring System (1) according to Claim 6, wherein said at least partially extended condition is a condition in which the bellow (2) is completely extended.

8. Monitoring System (1) according to any one or more of the previous claims, wherein the capping device (10) is an aseptic or ultraclean capping device (10), the second environment (PE) is a protected environment which is aseptic or ultraclean, and the first environment (OE) is not aseptic and not ultraclean.

9. Capping device (10) for capping containers (B), comprising:a monitoring system (1) according to any one or more of the previous Claims;said capping head (101).

10. Capping device (10) according to Claim 9, wherein:the monitoring system (1) is according to Claim 6 or according to Claim 6 and any one or more of Claims 7 and 8;the actuator (7) is for vertically moving the capping head (101) also in a production mode of the capping device (10) in which the capping device (10) is capping containers (B), the control device (4) being configured for checking said integrity in a check mode of the capping device (10), in which the capping device (10) is not capping any container.

11. Capping device (10) according to Claim 9 or 10, comprising a barrier (6) to which said bellow (2) is attached to follow said vertical movement, said bellow (2) and said barrier (6) being spatially interposed between said first environment (OE) and said second environment (PE) to delimit each of said first environment (OE) and said second environment (PE).

12. Capping device (10) according to any one or more of Claims from 9 to 11, wherein the capping device (10) is an aseptic or ultraclean capping device (10), the second environment (PE) is a protected environment which is aseptic or ultraclean, and the first environment (OE) is not aseptic and not ultraclean.

13. Packaging apparatus for packaging a pourable product by means of containers, comprising a capping device (10) according to any one or more of Claims from 9 to 12.

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