CONTAINER HYGIENE AND FIUUING UIQUID

FIEUD OF INVENTION The present invention relates to an apparatus and method for providing a portable and comprehensive facility for point-of-use product formulation and packing of any liquid products in reusable containers to reduce the logistics carbon footprint, to reduce the single-use packing waste generation and to promote a circular economy based reuse of packing material. More specifically, the present invention relates to an apparatus and method for providing container unique identification mechanism based management for use and reuse of container and container hygiene procedure compliance assurance system.

BACKGROUND OF INVENTION

The products are processed and packed in a centralized factory and then transportation is required to make them reach to the consumers for consumption. Many products can be sourced locally e.g., water and water-based beverage like flavoured water. For these kinds of products transportation, its cost and environmental impact like carbon footprint can be saved if the product formulation and packing can be done at the point-of-use. And for packing of product mostly single-use packing is in use e.g., single-use plastic bottle for packing of drinking water, this single-use packing material can be replaced with a reusable container to prevent the packing waste generation to save the cost and environmental impact.

For this purpose, point-of-use packing facility is needed with reusable container management and hygiene assurance system. So, to reduce the single-use packing waste generation, and to reduce the carbon footprint of transportation of products, there is a need for portable and comprehensive apparatus and method which satisfy the need for point-of-use product formulation and packing facility with product quality control, container hygiene facility with IoT and AI-based auto controls and reporting facility.

Patent bearing No. US20170166341A1, Filed by Dai Nippon Printing Co Ltd., Dated: 28/02/2017, Discloses the beverage filling method and apparatus in which, only a bottle properly preliminarily heated is sterilized by hydrogen peroxide. Temperature inspection to the bottle is performed while travelling the bottle. During the inspection, a bottle of which temperature does not reach a predetermined temperature is removed and a bottle of which temperature reaches the predetermined temperature is continuously travelled, hydrogen peroxide condensed mist a is blown toward a mouth portion 1 a of the bottle by a spray tube 59 disposed at a predetermined position, and hot air is blown into the bottle from the nozzle while the nozzle 64 following the mouth portion of the bottle. According to such operation, only the bottle properly heated can be sterilized by the hydrogen peroxide, Thereafter, beverage fills the bottle, which is then sealed.

Patent bearing No. US3605827A, Filed by U S BOTTLERS MACHINERY CO, Dated: 04/08/1969, Discloses a rotary filling machine having spaced cam-controlled filler heads or units with depending filling stems which are automatically lowered and raised for accurate material, filling of containers or bottles of any suitable material, each filler head when lowered enters its filling stem in the opening or neck or a container, sealing and air sensing its container before filling, and rejoicing a defective container whereby only those containers which are leak-proof under air pressure are filled with the desired volume of the liquid produce the filling head or unit includes a flexible sensing diaphragm and a ported plunger providing an air valve, and a flexible diaphragm and plunger having a valve controlling product flow, each operated by an air flow system, and vacuum signals determining when to commence filling and when to stop.

Patent bearing No. US7328558B2, Filed by KHS Maschinen und Anlagenbau AG, Dated: 31/01/2006, Discloses a beverage bottling plant for filling bottles with a liquid beverage filling material, a container filling plant container information adding station, such as, a labelling station, configured to add information to containers, such as, bottles and cans, and modules for labelling stations proposed a labelling machine. Each module comprises a first coupling structure to permit interchangeable position of a module at one of a plurality of second coupling structures.

Patent bearing No. US10000304B2, Filed by Arthur MONCAYO, JR., Dated: 19/05/2014, Discloses some aspects to methods and apparatuses for sterilizing, sanitizing, and/or otherwise removing contaminants from, filling, and/or capping containers, such as bottles. In some aspects, the containers are reusable bottles containing or designed to hold drinking water. In some embodiments, the container is received from a customer and/or is provided to the customer. In some embodiments, the methods include returning the same container to the customer. In some embodiments, the methods provide sanitary, convenient, and/or environmentally-friendly alternatives to available methods for removing cleaning, sanitizing, sterilizing, filling, and capping of containers holding drinking liquids.

Patent bearing No. US9731845B2, Filed by Evive Station LLC, Dated: 07/12/2016, Discloses a vending machine comprising multiple subsystems typically including container receiving, container cleaning, container storage, container filling, container vending, a computer system, and a user interface. A vending machine for dispensing, receiving, cleaning and/or filling containers comprising container receiving means for receiving a first container, container cleaning means for cleaning the first container, container dispensing means for dispensing the first container, and container filling means for filling the first container or a second container.

The machine arrangements for filling and sealing containers are known from the prior art in different configurations. Previous machine concepts for filling and closing containers are usually based on a series arrangement in which the container passes through several processing stations in a row, with transport or handling steps being necessary between the individual stations. Such machine arrangements are rather unsuitable for small or point-of-use batch applications and they are not equipped with water purification and dosing facility attached to it, and since the known machine arrangements are designed for large and centralized throughputs and monotones job and they don’t facilitate container change over without changing the system or settings of the machine, and continuous operation with different capacity and shape of container in a single run, and they don’t facilitate container hygiene procedure compliance assurance reporting feature, they don’t facilitate IoT based product quality control and monitoring, programmable dosing facility, and automated batch manufacturing record preparation.

However, each of the aforementioned technologies lacks in one or other aspects when compared to present invention. There is a need to use a reusable container with life tracking and hygiene assurance method for filling purposes to reduce packing waste by means of reuse of packing material in circular economy principle and to reduce the logistics carbon footprint employing point-of-use or in-house product formulation and packing.

Thereby, the general purpose of the present invention is to provide an improved combination of convenience and utility, to include the advantages of the prior art, and to overcome the drawbacks inherent therein. SUMMARY OF THE PRESENT INVENTION

The principal object of the present invention is to overcome those limitations of prior arts and to facilitate the de-centralized or point-of-use product formulation with water purification and substance dosing, container hygiene compliance assurance with container unique identification system and packing facility.

One of the object of the present invention is to facilitate the packing of different capacity and shape of containers in continuity and a single batch without need of a change of setting of apparatus or batch change over.

One of the object of the present invention is to provide the facility of product formulation and water purification facility to make purified water available and metered dosing facility for formulation for dosing of substance like herbal or botanical extract, flavours, gas, minerals, active ingredient or any other substance and to the facility of sensor, control unit and software program-based monitoring, controlling, and reporting of the parameter of product, water, and dosing substance.

One of the object of the present invention is to provide a hygiene procedure which includes washing, brushing, rinsing and sterilisation of containers. In which the brushing station for brush washing of container, rinsing station for rinsing of the washed container and sterilization station for sanitation of container after rinsing.

One of the object of the present invention is to provide a various stations for filling liquid, product formulation and container hygiene procedure.

One of the object of the present invention is to provide a gripper assembly which is used to holding the container. The gripper assembly mounted on conveying mechanism for moving from one station to another with container.

Another object of the present invention is to provide a facility for container (including reusable container) automatic metered filling and to confirm the hygiene procedure compliance to fill or reject the container. And to detect the volumetric capacity of the container from the container unique identification code and to fill the container with the mentioned amount/volume of the product.

Another aspect of the present invention is to provide an apparatus and method for product formulation which comprises a water purification device and substance dosing setup which is controlled and monitored by a software program wherein product formulation parameters such as substance dosing, water purification, monitoring the TDS (Total Dissolved Solids) and pH of water can be changed and programmed through an input-output device like a touch screen.

Another aspect of the present invention comprises a method of providing unique identification to a container. An unique identification of container is a coding of a container with Quick Response Code (QR Code), Bar Code and/or radio-frequency identification, printed, engraved, marked, and/or affixed on the container with the help of any printing, fixing or marking technology. This code may contain a serial number of containers which should be unique and the volumetric capacity of a container, etc. The container unique identification code facilitates the management of use and reuse of containers with container life tracking, hygiene procedure compliance tracking and container volumetric capacity detection for automated metered filling at filling station, etc.

Yet another aspect of the present invention is to provide apparatus and method for capping and sealing of filled container which comprises a cap holding chamber, cap fastening device and tamper-proof sealing device for capping and sealing of the filled container.

Yet another aspect of the present invention is to provide a method for BMR(B are-metal restore) based which is one of the software -based system for preparation of reports and web based reporting, wherein there is a system for batch manufacturing report preparation and other report preparation like preventive maintenance report, container usage report etc., based on data collected and communicated by a control unit to a server by using modem and connection facility like SIM card, WI-FI or Bluetooth, other machine-to-machine communication tool, etc. This device is run by the control unit, program and input-output devices like a USB port and touch screen device.

Another aspect of the present invention is to provide a process for filling the liquid which starts with loading of the container 10 at station 1. At Station 3, the container 10 does a 180-degree spin and moves forward to Station 4. At station 4, water is sprayed into the container prior to brushing to create moisture inside the container 10 and ensure a frictionless procedure. The brushing procedure begins at station 5, where the container 10 is cleansed with water and brush. As per the size of the container the position of the motor is adjusted. After brushing of the container rinsing process need to be done by using hot water at station 6. The container 10 required to sterilize at station 8, the container is sterilized through UV-C Light using UV-tube. The container again turns 360° and then container fills with the liquid at station 9. The container then move ahead for capping process, at station 11 Lug or ropp cap or any other container closure like lid feeding on the container is done then the container arrived at station 12 for sealing the cap head on the container and in the end batch information printing is done on the container 10 through laser printing 58. And after that again at station 1, unloading of the container 10 is done after container 10 filled with the liquid. Station 2, station 7 and station 10 are provided as blank spaces and it should be incorporated when required.

BRIEF DESCRIPTION OF DRAWINGS

The advantages and features of the present aeration apparatus will become better understood with reference to the following more detailed description taken in conjunction with the accompanying drawings in which:

Fig. 1 illustrates flow chart explaining the process for filing liquid,

Fig. 2 illustrates the apparatus for filling liquid,

Fig. 3 illustrates the schematic diagram of gripper assembly,

Fig. 4 illustrates the 3D view of gripper assembly,

Fig. 5 illustrates the schematic diagram of station 1,

Fig. 6 illustrates the schematic diagram of station 4,

Fig. 7 illustrates the schematic diagram of station 5,

Fig. 8 illustrates the schematic diagram of station 6,

Fig. 9 illustrates the schematic diagram of station 8,

Fig. 10 illustrates the schematic diagram of station 9,

Fig. 11 illustrates the schematic diagram of station 11,

Fig. 12 illustrates the diagram of vibration bawl feeder,

Fig. 13 illustrates the schematic diagram of station 12,

Fig. 14 illustrates flow chart explaining the product formulation,

Fig. 15 illustrates the unique identification code of the container.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details. Reference herein to “one embodiment” or “another embodiment” means that a particular feature, structure, or characteristics described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in a specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the diagrams representing one or more embodiments of the invention do not inherently indicate any particular order nor imply any limitations in the invention.

As used herein, the term “plurality" refers to the presence of more than one of the referenced item and the terms “a”, “an”, and “at least” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

The term ‘parameter’ is used in the following description for product, water, and dosing substance such as formulation of product for filling, metered dosing of substance, monitoring the TDS and pH of purified water.

The term ‘control unit’ is used in the following description for programmable logic controller. The term ‘container’ is used in the following description indicates any container with at least one opening such as bottle, glass, can and Indian pot, etc. made of any material like glass, metal or any other material, the term container also includes the term reusable container.

The geared motor is referred as ‘a motor’ interchangeably used herein the following description. The closure provided on the container like lug or ropp cap or any other container closure like lid is referred as ‘a cap’ in the following description.

An embodiment of the present invention is to provide a portable and comprehensive apparatus for product formulation and packing facility. The present invention facilitates the product formulation with water purification which can also facilitates customized purification like alkaline water and substance dosing, container hygiene compliance assurance with container unique identification system, washing and sterilization facility, identification code based automated capacity detection and metered filling of the container, capping and tamper-proof sealing of container and batch coding on containers including reusable containers and product parameter and container hygiene controlling, monitoring and reporting feature. Another embodiment of the present invention is to provide an apparatus for hygiene of container and container unique identification code -based hygiene procedure compliance tracking which comprises an empty container with a unique identification code placed at each station for hygiene procedure wherein, i. At least one brushing station consist of a wire brush connected with a motor for rotation, water sprayed inside an empty container for developing moisture before brushing then it is going to be washed using a brush then apparatus records the details of an empty container using a code scanner and sent it to the control unit and moving to the next station for rinsing; ii. At least one rinsing station consist stainless steel spray nozzle connected with a pump to transport the liquid inside the empty bottle for rinsing, wherein an empty container is rinsed using hot water then apparatus records the details of an empty container using code scanner and sent it to control unit and moving to the next station for sterilization; iii. At least one sterilization station consist germicidal ultraviolet light, wherein an empty container is sterilized using UV-C light exposure inside and outside of the container then apparatus records the details of an empty container using code scanner and sent it to control unit.

Another embodiment of the present invention is to provide an apparatus for capping and sealing of filled container which comprises a cap feeding station, cap fastening device and tamper proof sealing device for capping and sealing of the filled container.

Another embodiments for cap holder is a metal jacket to hold the cap and cap fastening device consist capping mold connect with a motor.

Another embodiment of the present invention is to provide a method of tracking, recording and reporting of compliance of container hygiene procedure wherein the unique identification code of the container is scanned by a code scanning device installed at brushing, rinsing and sterilization chambers and the scanned code is recorded by the control unit for further processing like for confirmation of hygiene procedure compliance at filling station and for batch information printing and reports preparation.

The flow chart depicted in Figure 1 of the present invention explains the method of filling the liquid. Brushing, rinsing, and sterilizing the container 10 before filling is part of the container hygiene process. During the brushing procedure, an empty container 10 was washed with brush 19. After that, container 10 is sterilized with UV-C light via UV-tube 23 after a rinse process with hot water.

On the completion of the each process brushing, rinsing and sterilisation, an apparatus records the unique identification code of a container 10 using code scanner and sent it to control unit.

After the hygiene procedure an empty container 10 placed at the filling station wherein, an apparatus read the volumetric capacity of a container 10 using a code scanner, from the unique identification code of the container and receive confirmation regarding an empty container is passing through all the hygiene stations of washing and disinfecting using the controller; if confirmation about passing through all the above three stations not received then apparatus will not fill an empty container 10 and it will be sent back to pass through all three previous stations. And if the passing confirmation from hygiene procedure stations is received then apparatus fills an empty container 10 with a volume of the product as specified in identification code and send the data to control unit, in one of the embodiment filling station consist stainless steel or any other metal like copper tap connected to product tank/chamber through pipe and pump system to transport the product to fill the container 10.

After completion of filling process container placed at sealing compartment wherein, an apparatus collects the cap at the opening of the container 10 from cap holder and fastening of the cap on the filled container 10 and tamper-proof sealing of container 10. After capping and sealing, the sealed container is arrives for batch coding process, where a printer collects the data from the control unit and prints data like hygiene procedure compliance assurance, date of packaging, expiry date/shelf life, product quality parameter, the authenticity of packing, etc. on the container 10. At the end of the process the data is transferred from control unit to the server. The data of operations collected or generated by a control unit send to a server using modem.

Figure 2 of the present invention discloses apparatus 100 for filling the liquid. The apparatus 100 for filling liquid includes a conveying mechanism 54 with plurality of sprocket wheels 55, a gripper assembly 101, and different stations for liquid filling, product formulation, and container hygiene. The procedure of filling the liquid begins at station 1 with the loading and emptying of the container. At Station 3, the container 10 does a 180° spin and moves forward to Station 4. At station 4, water is sprayed into the container prior to brushing to create moisture inside the container 10 and ensure a frictionless procedure. The brushing procedure begins at station 5, where the container 10 is cleansed with water and brush. As per the size of the container the position of the motor is adjusted. After brushing of the container rinsing process need to be done by using hot water at station 6. The container 10 required to sterilize at station 8, the container is sterilized through UV-C Light using UV-tube. The container again turns 360° and then container fills with the liquid at station 9. The container then move ahead for capping process, at station 11 a cap feeding on the container is done then the container arrived at station 12 for sealing the cap head on the container and in the end batch information printing is done on the container through laser printing 58. And after that again at station 1, unloading of the container 10 is done after container 10 filled with the liquid. Station 2, station 7 and station 10 are provided as blank spaces where any product-specific process can be added at any moment.

Figure 3 of the present invention discloses the schematic diagram of gripper assembly lOl.The container 10 hold by the gripper assembly 101 for various purpose such as washing, filling, turning etc. at different station. The gripper assembly 101 is connected to the conveying mechanism 54 by using plurality of screws 57A and 57B which are attached with the main holder 1. Further gripper assembly 101 comprises main holder 1 which includes the pushing pin 3 for pushing the compression spring 4 further for operating the operating lever 7 which is attached to the compression spring 4 through the pushing knob 6 then the operating lever 7 connected to the holding jaws 9 through the inner and outer linkage and the holding jaws 9 that can be adjusted as per different size of the container 10 wherein the inner linkage 8A and outer linkage 8B attached to the main holder 5 at one end and to the holding jaws 9 at other end and the main holder 5 having the turning plate 3 with the bearing 59 for rotating the gripper assembly 101 to the appropriate degree such as 180° or 360°.

Figure 4 of the present invention discloses the schematic diagram of station 1. Loading and unloading of the container 10 is done at station 1 by actuating the pneumatic cylinder 11 attached by bracket 12 to the gripper assembly 101.

Figure 5 of the present invention discloses the schematic diagram of station 4. Water spraying is required prior to the brushing procedure in order to produce moisture inside the container 10, which allows for frictionless brushing. At station 4, a water tank 17 is available for water spraying. Water is sprayed inside the container 10 from the spraying nozzle 18, and the pump 14 is connected to the water tank 17 for supplying water from the water tank 17, and then water is sprayed inside the container 10 from the spraying nozzle 18 through the flexible tube 13 provided for flexibility for water spraying. The water level in the water tank 17 is maintained by the low level ball valve 15, and the water level in the water tank 17 is measured by the low level sensor 16.

Figure 6 of the present invention discloses the brushing process at station 5.The container 10 held by the gripper assembly 101 is brushed from inside through the brush 19 which is attached with the geared motor 21.A motor 21 is supported by the main holder 20 and connected to the pneumatic cylinder 22. As per the size of the container 10 motor 21 is adjusted through pneumatic cylinder 22.

Figure 7 of the present invention discloses the brushing process at station 6.The container 10 which is held by the gripper assembly 101 is going to be rinsed through hot water at station 6.The water is heated by the electric heater 47 and then thermocouple 46 measures the temperature of the hot water so that water heated at appropriate temperature. After that hot water in the water tank 50 pumped through the pump 49 and supply to the flexible tube 45 which is adjusted by bakelite knob 42 connected to the rod 44. The container 10 then rinsed from inside through hot water using the spraying nozzle 41. The low level sensor 48 measures the level of the water in the water tank 50. The used water after rinsing again drove back to the water tank 50 after foreign particle from the liquid retain through the strainer 43.

Figure 8 of the present invention discloses the schematic diagram of station 8.At station 8, sterilization of the container 10 from inside and outside is done through UV-C light by using UV-Tube 23.The UV-Tube 23 is covered by the cover 24.

Figure 9 of the present invention discloses the schematic diagram of station 9.The container 10 turned 360° and filled with the liquid at station 9.The solenoid valve 25 shut off and allow the flow of liquid from the water tank 30 and then water flow through the flexible tube 26 attached to the pipe 28 which provide the flexibility for the liquid filling. The pipe 28 is supported and held by the pipe holder 29 and can be adjusted by using the bakelite knob 27.

Figure 10 of the present invention discloses the schematic diagram of station 11. after filling the liquid the container 10 move forward to the station 11 for cap feeding. Figure 11 of the present invention discloses the diagram of vibration bawl feeder. A vibration bawl feeder supplies the cap to the cap holder. A vibration bawl feeder able to handle various size of cap as per the size of the container lO.The cap holder 38 is connected to the torque motor 31 which is supported by the motor holder 32. The cap holder 38 operated by the torque motor 31 for feeding the cap on the container 10. The cap adjusted by the pusher assembly 40 which is connected to the guide 39 for moving in linear direction. The pneumatic cylinder 33 actuated for the movement of the supporting member connected to the upper mounting frame 35 on which the pneumatic cylinder 34 is mounted. The lower mounting frame 37 to be lowered for small size containers. Both the frame supported by the supporting frame 36.

Figure 12 of the present invention discloses the schematic diagram of station 12.The cap need to be sealed after feeding the cap at station 11 on the container 10 which is held by the gripper assembly 101. Then the container 10 moved further for the laser printing. The suitable printing head 53 need to fix in the holder 52 which is adjusted by the bakelite knob 51.The printing head 53 prints data like hygiene procedure compliance assurance includes time of hygiene process, date of packaging, expiry date/shelf life, product quality parameter, the authenticity of filling, etc. on the container 10 through laser printing.

Figure 13 of the present invention discloses flow chart explaining the product formulation. The product formulation comprises water purification which can also facilitates customized purification like alkaline water and other water treatment by using water purification device and substance dosing. Water is required to purify before dosing process. After water purification the purified water then dosed with the substance. The dosing tank is provided for dosing of the substance. The product formulation process is done before the water filling process at station 9. The product formulation controlled by IoT and AI based quality control feature which includes maintenance of TDS level etc.

Figure 14 of the present invention discloses about the unique identification code for the container. An unique identification code is any kind of unique coding mechanism like Quick Response Code (QR Code), Bar Code and/or radio -frequency identification, printed, engraved, marked and/or affixed on the container 10 with the help of any printing, fixing or marking technology. Wherein, an identification code may comprise at least numeric digits containing information of serial number of containers; at least alphanumeric code containing information of machine user or machine identification code and at least information of capacity of container 10. The formation of identification code comprises following:

XXXX/YYYY/ZZZZ

Wherein,

XXXX denotes volumetric capacity of container.

YYYY denotes information of machine or machine identification code. ZZZZ denotes unique serial number of the container.

The present invention does not limit its scope by considering above mentioned format of identification code; it can be in any format.

Although a particular exemplary embodiment of the invention is disclosed in detail for illustrative purposes, it will be recognized to those skilled in the art that variations or modifications of the disclosed invention, including the rearrangement in the configurations of the parts, changes in steps and their sequences may be possible. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as may fall within the spirit and scope of the present invention. The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching.