Technical Field

The present invention relates to a facility designed for filling packages in a pressure-sealed chamber, and a method of filling. It relates to food processing, where the invention is used to fill the packages with beverages, but may also refer to the industrial use, as long as the invention would be used to fill packages with non-food fillings, for example, with medical drugs.

The Current State of the Art

Nowadays, several principles are used for filling of products, such as liquid substances, to packages, e.g. the gravity level filling, under- or overpressure filling, as well as volumetric filling, or filling on the principle of weighing. Currently, the filled package goes through various chambers in the processes from package preparation to its filling and sealing. During filling and sealing, there is air swirling, which can cause secondary contamination of the filled product. For example, when filling the carbonated beverages, the package, once filled, is located in the chamber, where it is pressurized, then it moves into the chamber with atmospheric pressure, and then it is sealed. However, this spatial movement negatively affects the quality of carbonation of the beverage and creates a potential risk of secondary contamination.

Principle of the invention

The facility for filling packages in a pressure-sealed chamber, according to the invention, consists of two basic parts, i.e. the static part and the rotating pail.

According to the invention, the operating elements are connected to the static part of the facility: a multifunctional sterilizing needle, a filling head, a sealing head, a bottom valve, and a package carrier. There are operating element drives, a storage tank of the filled product, and the media feed lines located above the static part of the facility. The rotating part of the facility is connected to a shaft that passes through the static part. The shaft is terminated at the bottom by the package carrier and the rotating part carrier. In the rotating part, there is an opening with a seat for sealing the bottom valve, and an opening to insert the package.

According to the invention, a storage tank of the filled product, a peroxide evaporator, an air exchanger, and a sanitation pipe are connected by pipes to the facility, which can be attached to the support frame of the facility according to the invention.

According to the invention, the facility is connected to a sanitation circuit, through which the pipes, valves, and the entire filling chamber are purged after the production batch was completed.

According to the invention, the facility can also be designed without a rotating part, wherein the following operating elements are connected to the static part of the facility according to the invention: a multifunctional sterilizing needle, a filling head, a sealing head, a bottom valve and a package carrier. There are operating element drives, a storage tank of the filled product, and the media feed pipes located above the static part.

According to the invention, the facility is controlled by Programmable Logic Controller (PLC).

According to the invention, the facility can be attached to a supporting base frame, to which an input conveyor can be attached to supply empty packages to the facility. In addition, an output conveyor can be attached to the frame to remove filled packages from the facility, and a conveyor to feed the caps to the facility, according to the invention.

According to the invention, conveyors to feed/remove the packages and caps to/from the facility may be replaced by another suitable method or device.

The method of filling the package in a pressure-sealed chamber with both, the static and rotating pails, of the facility is based on the fact that a cap is conveyed to the sealing head, which is in the lower position, and the sealing head moves upward along with the cap.

An empty package is inserted into the package carrier, which is subsequently sealed with the bottom valve by being pressed against the seat of the rotating part, 'this seals the filling chamber and separates it from the external environment.

The rotating part is set to position No. 1 -· sterilization. Sterilization by peroxide requires a peroxide concentration of min. 35%. The peroxide/air mixture is heated in the peroxide evaporator heating body to a minimum of 70 °C according to the selected/used packaging material.

By opening the peroxide-sterilizing valve and, subsequently, by opening the discharge valve, a mixture of peroxide and air is injected through the sterilizing-multifunction needle into the empty package, filling chamber, and onto a cap. Subsequently, the peroxide-sterilizing valve and the discharge valve are closed. Treatment with peroxide for the necessary time, depending on the packaging used, sterilizes the filling chamber, package, and the cap.

By opening the air-sterilizing valve to supply the hot sterile air, and by opening the discharge valve, the filling chamber, package, and the cap are purged through the multifunctional sterilizing needle by the pressure of the pre-prepared sterile hot air. Air pre-prepared in the air exchanger must be heated to a minimum of 100 °C according to the selected/used material of packaging. The pressure of the sterile hot air thus prepared must be at least 0.1 bar. The filling chamber and package can then be filled with inert gas, e.g. with N ₂ , from an inert gas tank, or with CO ₂ gas.

The rotating part is set to position 2 - filling. In tills step, the pressure in the product storage tank is first adjusted to the pressure in the filling chamber. The filling process begins by opening the filling head. After the required volume controlled by the flow meter or other measuring device was filled, the filling head is closed.

The rotating part is set to position 3 - sealing. The sealing head seals the filled package by moving downwards, in some types of packages also by simultaneous rotation. When the filled package was closed, the sealing head returns to the top starting position. The filled and sealed package is removed from the package carrier.

Subsequently, the entire process is repeated from the insertion of the cap and package to the facility according to the invention, through subsequent sterilization, filling, sealing, to the removal of the filled package.

The method of filling the package in a pressure-sealed chamber on the facility with only the static part consists in the fact that the cap is conveyed to the sealing head, which is located at a lower position above the opening for inserting the package, followed by the sealing head moving upwards and turning to an intermediate position so as not to prevent another operating element from operating. An empty package is inserted into the package carrier; it is then sealed by being subsequently pressed against the seat of the static part. This will close the filling chamber and separate it from the outside environment.

Sterilization by peroxide requires a peroxide concentration of min. 35%. The peroxide/air mixture is heated in the peroxide evaporator heating body to a minimum of 70 °C according to the selected/used packaging material.

After closing the filling chamber, the sterilizing - multifunctional needle is set to a position above the empty package. By opening the peroxide-sterilizing valve and, subsequently, by opening the discharge valve, a mixture of peroxide and air is injected through the sterilizing- multifimction needle into the empty package, filling chamber, and onto a cap. Subsequently, the peroxide-sterilizing valve and the discharge valve are closed. Treatment with peroxide for the necessary time, depending on the packaging used, sterilizes the filling chamber, package, and the cap. By opening the air-sterilizing valve to supply the hot sterile air, and by opening the discharge valve, the filling chamber, package, and the cap are purged through the multifunctional sterilizing needle by the pressure of the pre-prepared sterile hot air. Air preprepared in the air exchanger must be heated to a minimum of 100 °C according to the selected/used material of packaging. The pressure of the sterile hot air thus prepared must be at least 0.1 bar.

The filling chamber and package can then be filled with inert gas, e.g. N ₂ , from an inert gas tank, or with CO ₂ gas.

The multifunctional sterilizing needle is set to its initial position so that it does not hinder the next operating element from operating.

After the multifunctional sterilizing needle moves to a position, the pressure relief valve first opens, thus equalizing the pressure in the storage tank of the filled product with the pressure in the filling chamber. The filling process starts by opening the filling head. After the required volume as controlled by the flow meter or other measuring device was filled, the filling head is closed. The operating element-the sealing head is set above the neck of the package. The sealing head seals the filled package by moving downwards, in some types of packages also by simultaneous rotation. After the filled package was sealed, the pressure relief valve is closed, and then a discharge val ve is opened, through which the pressure in the filling chamber is adjusted to the ambient pressure. After the tilling chamber was depressurized, the sealing head returns to the upper starting position. The filled and sealed product package is removed from the package carrier.

Subsequently, the entire process is repeated from insertion of the cap and package to the facility according to the invention, through subsequent sterilization, filling, sealing, to the removal of the filled package.

All these steps take place in a closed filling chamber, which is the main and most important benefit of this filling method over the prior state-of-the-art. The facility and method of filling according to the invention in a pressure-sealed chamber provides high purity to sterility of filling. In the above processes, the package is sealed before it leaves the filling chamber.

In case of carbonated beverages, this means that the package is sealed under pressure. The standard filling method requires releasing the filling overpressure to atmospheric pressure after the package was filled, causing foaming of the beverage and loss of carbonation gas in the product, e.g. CO ₂ . The filling process does not relieve pressure before sealing, which is an apparent advantage. The facility and the method of filling, according to the invention, allow for more efficient filling of carbonated beverages. The facility and the method of filling, according to the invention, do not exclude the possibility of omitting any of the steps, for example sterilization, air exchange for an inert gas, and the like.

The facility and the method of filling, according to the invention, are intended for filling conventional packages, such as e.g. PET packaging, HDPE packaging, glass packaging, aluminum packaging, doy-pack packaging, and cardboard packaging.

In a standard way of filling, secondary contamination from the surrounding area cannot be excluded. When using the facility and the filling method according to the invention in a pressure-sealed chamber, there is no secondary contamination of the beverage from the surroundings. Description of Terms Used to Explain the Subject Matter of the Invention:

Packaging filling facility - A facility, in which the product filling process takes place

Pressure-sealed chamber - A chamber, in which the required pressure can be maintained Product - Milk, beer, wine, lemonade, baby food, juice, carbonated and non-carbonated drinks, medicines and similar liquid substances

Sterilization - A physical or chemical process, which destroys all microorganisms in a given environment, object or equipment

Carbonated drink - A drink enriched with carbon dioxide or other inert gas

Sterilization-multifunctional needle - A duct leading to a filling chamber, through which a mixture of peroxide with air, sterile air, or an inert gas are injected into the filling chamber Filling head - The pipe termination to fill the product from the storage tank to the empty package

Sealing head - Used to firmly attach the cap to the package and close it

Bottom valve - A valve to close the opening after the cap was inserted into the sealing head

Package carrier - Used to move the package to and from the facility

Rotating part carrier - Used to move the rotating part

Storage tank of the filled product - The tank, through which the product passes, and which is designed to prevent contamination of the product from the environment and, at the same time, to maintain the required filling pressure

Overview of Images in the Figures

Figure 1 shows a static part of the facility according to the invention.

Figure 2 shows a rotating part of the facility according to the invention.

Figure 3 shows three basic positions of the filling facility during the operating cycle.

Figure 4 shows a filling facility in the sterilization position.

Figure 5 shows a filling facility in the filling position.

Figure 6 shows a filling facility in the sealing position.

Figure 7 shows the principle of the filling facility as a whole, without the rotating part.

Figure 8 shows a filling facility without a rotating part in the sterilization position. Figure 9 shows a filling facility without a rotating part in the filling position.

Figure 10 shows a filling facility without a rotating part in the sealing position.

Figure 11 shows the principle of a filling facility as a whole, without a rotating part and a bottom valve.

Figure 12 shows a filling facility without a rotating part and a bottom valve, in a sterilization position.

Figure 13 shows a filling facility without a rotating part and a bottom valve, in a filling position.

Figure 14 shows a filling facility without a rotating part and a bottom valve, in the sealing position.

Figure 15 shows whole filling facility. This figure is proposed to be published together with abstract.

Examples of Embodiment of the Invention

Example 1

The facility for filling packages in a pressure-sealed chamber shown in figures 1 to 6 consists of two basic parts, the static part 1 and the rotating part 2.

Operating elements are attached to the static part of the invention: a multifunctional sterilizing needle 11, a filling head 10, and a sealing head 9. There are operating element drives and media feed lines located above the static part of the facility 1.

The rotating part of the facility 2 is connected to the shaft 13 passing through the static part 1. The shaft 13 is terminated in the lower part by the package carrier 4 and the rotating part carrier 14. In the rotating part 2, there is an opening with a seat for sealing the bottom valve 15, and an opening for inserting packages 16.

A storage tank of the filled product 17, a peroxide evaporator 18, an air exchanger 19, and a sanitation pipe 26 that can be attached to the support frame of the facility according to the invention are connected to the filling head 10 via piping.

According to the invention, the facility is connected by the sanitation pipe 26 to the sanitation circuit, through which the pipes, valves, and the entire filling chamber 5 are purged after the production batch was completed. The method of filling the package in a pressure-sealed chamber according to the invention consists of the fact that the cap 20 is conveyed to the sealing head 9, which is in the lower position, followed by the sealing head 9 with the cap 20 moving upwards.

An empty package 3 is inserted into the package carrier 4, which is then sealed by being subsequently pressed to the package-insertion opening 16 in parallel with the bottom valve 12. Thereby, the filling chamber 5 is sealed and separated from the external environment. Rotating part 2 is set to position No. 1 - sterilization 6. By opening the peroxide sterilizing valve 21, and then by opening the discharge valve 25, a mixture of peroxide and air is blown through the multifunctional sterilizing needle 11 into the empty package 3, filling chamber 5 and onto the cap 20. Subsequently, the peroxide-sterilizing valve 21 and the discharge valve 25 are closed. By treatment with peroxide, the filling chamber 5, the package 3 and the cap 20 are sterilized. By opening the air-sterilizing valve 22 for the supply of the hot sterile air, and by opening the discharge valve 25, the filling chamber 5, package 3, and the cap 20 are pinged through the multifunctional sterilizing needle 11 by the pressure of the pre-prepared sterile hot air. The filling chamber 5 and the package 3 can then be filled with an inert gas through the inert gas valve 23, e.g. with N ₂ from an inert gas tank 24, or with CO ₂ gas.

Rotating part 2 is set to position No. 2 - filling 7. In this step, the pressure in the storage tank of the filled product 17 is first adjusted to the pressure in the filling chamber 5. Opening of the filling head 10 stalls the filling process. After filling the required volume as controlled by a flow meter or other measuring facility, the filling head 10 is closed.

Rotating part 2 is set to position No. 3 - sealing 8. The sealing head 9 closes the filled package by moving downward; in some types of packages by simultaneous rotation. After closing the filled package 3, the pressure in the filling chamber 5 adjusts to the ambient pressure via the discharge valve 23. After the filling chamber 5 was depressurized, the sealing head 9 returns to the upper starting position. The filled and closed product package 3 is removed from the package carrier 4.

Example 2

The facility for filling packages in a pressure-sealed chamber shown in figures 7 to 10 consists of a static part 1, to which the following operating elements are connected: a multifunctional sterilizing needle 11, a filling head 10, a sealing head 9, a bottom valve 12, and a package carrier 4. There are operating element drives and the media feed lines located above the static part 1 , The package 3 and the cap 20 are in this case at a stable position; above this position, the operating elements alternate, i.e. the multifunctional sterilizing needle 11, the filling head 10 and the sealing head 9.

The method of filling the package in a pressure-sealed chamber according to the invention consists in the fact that the cap 20 is conveyed to the sealing head 9, which is in the lower position, and subsequently the sealing head 9 moves with the cap 20 upwardly and turns into the intermediate position so as not to hinder another element from operating. An empty package 3 is inserted into the package carrier 4, and is then sealed by being subsequently pressed to the package-insertion opening 16 in parallel with the bottom valve 12. Thereby the filling chamber 5 is sealed and separated from the external environment.

After closing the filling chamber 5, the multifunctional sterilizing needle 11 is set to a position above the empty package 3. By opening the peroxide-sterilizing valve 21 , and then by opening the discharge valve 25, a mixture of peroxide with air is blown from the peroxide evaporator 18 through the multifunctional sterilizing needle 1 1 to the empty package 3, the filling chamber 5 and the cap 20. Subsequently, the peroxide-sterilizing valve 21 and the discharge valve 25 are closed. By treatment with peroxide, the filling chamber 5, the package 3, and the cap 20 are sterilized. By opening the air- sterilizing valve 22 for the supply of the hot sterile air, and by opening tire discharge valve 25, the filling chamber 5, the package 3, and the cap 20 are purged through the multifunctional sterilizing needle 11 by the pressure of the pre-prepared sterile hot air. The filling chamber 5 and the package 3 can then be filled with an inert gas through an inert gas valve 23, e.g. with N ₂ from an inert gas tank 24, or with CO ₂ gas. The multifunctional sterilizing needle 11 is set to the initial position so as not to hinder any other operating element from operating.

After the multifunctional sterilizing needle 11 moved to its position, the pressure relief valve 27 is first opened, thereby equalizing the pressure in the storage tank of the filled product 17 with the pressure in the filling chamber 5. The opening of the filling head starts the product filling process. After the desired volume as controlled by the flow meter or other measuring device was filled, the filling head 10 is closed.

The operating element, i.e. the sealing head 9 is set above the neck of the package. The sealing head 9 seals the filled package by moving downwards; in some types of packages by simultaneous rotation. After closing the filled package 3, the pressure relief valve 27 is closed, and then the discharge valve 25 is opened, through which the pressure in the filling chamber 5 is adjusted to the ambient pressure. After the filling chamber 5 was depressurized, the sealing head 9 returns back to the upper starting position, and the bottom valve 12 opens. The filled and closed product package 3 is removed from the package carrier 4.

Example 3

The facility for filling packages in a pressure-sealed chamber shown in figures 11 to 14 consists of a. static part 1, to which the following operating elements are attached: a sterilizing-multifunction needle 11, a filling head 10, and a sealing head 9. There is a package carrier 4 and a cap carrier 28 located below the static part 1. There are the operating element drives and media supply lines located above the static part 1. In this case, the package 3 is in a stable position during the sterilization, filling and sealing processes, and the operating elements alternate above this position, i.e. the multifunctional sterilizing needle 11 , the filling head 10, and the sealing head 9.

The method of filling the package in a pressure-sealed chamber, according to the invention, consists in the fact that the cap 20 is conveyed by the cap carrier 28 to the sealing head 9, which is located at a lower position above the package-insertion opening 16, followed by the sealing head 9 with the cap 20 moving upwards and turning into an intermediate position so that not to hinder another operating element from operating. An empty package 3 is inserted into the package carrier 4, which is subsequently sealed by being pressed against the package insertion opening 16 in the static part. Thereby the filling chamber 5 is sealed and separated from the external environment.

After the filling chamber 5 was closed, the multifunctional sterilizing needle 11 is set to a position above the empty package 3. By opening the peroxide-sterilizing valve 21, and then by opening the discharge valve 25, a mixture of peroxide with air is blown from the peroxide evaporator 18 through the multifunctional sterilizing needle 11 to the empty package 3, filling chamber 5, and onto the cap 20. Then, the peroxide-sterilizing valve 21 and the discharge valve 25 are closed. By treatment with peroxide, the filling chamber 5, the package 3, and the cap 20 are sterilized. By opening the air-sterilizing valve 22 for the supply of the hot sterile air, and by opening the discharge valve 25, the filling chamber 5, the package 3, and the cap 20 are purged through the multifunctional sterilizing needle 11 by the pressure of the pre- prepared sterile hot air. The filling chamber 5 and the package 3 can then be filled with an inert gas through an inert gas valve 23, e.g. with N ₂ from an inert gas tank 24, or with CO ₂ gas. The multifunctional sterilizing needle 11 is set to the initial position so as not to hinder any other operating element from operating.

After the multifunctional sterilizing needle 11 was moved to its position, the pressure relief valve 27 first opens, thereby equalizing the pressure in the storage tank of the filled product 17 with the pressure in the filling chamber 5. The opening of the filling head starts the product filling process. After the desired volume of the product as controlled by the flow meter or other measuring facility was filled, the filling head 10 is closed.

The operating element, i.e, the sealing head 9 is set above the neck of the package. The sealing head 9 closes the filled package by moving downwards; in some types of packages by simultaneous rotation. After closing the filled package 3, the pressure relief valve 27 is closed, and then the discharge valve 25 is opened, through which the pressure in the filling chamber 5 is adjusted to the ambient pressure. After the filling chamber 5 was depressurized, the sealing head 9 returns to the upper starting position. The filled and closed product package 3 is removed from the package carrier 4.

List of relationship tags

Legend to the attached drawings - pictures No. 1-15:

1 Static part

2 Rotating part

3 Package

4 Package carrier

5 Filling chamber

6 Position No. 1 - sterilization

7 Position No. 2 - filling

8 Position No. 3 - sealing

9 Sealing head

10 Filling head

11 Multifunctional sterilizing needle 12 Bottom valve

13 Shaft

14 Carrier of the bottom rotating part

15 Opening with a seat to seal the bottom valve

16 Package-insertion opening

17 Storage tank of the filled product

18 Peroxide Evaporator

19 Air Exchanger

20 Cap

21 Peroxide sterilizing valve

22 Air-sterilizing valve

23 Inert gas valve

24 Inert gas tank

25 Discharge valve

26 Sanitation pipe

27 Pressure relief valve

28 Cap carrier

Industrial Usability

The facility and the method of filling in a pressure-sealed chamber, according to the invention, can be applied particularly in the food and pharmaceutical industries.