Cross Reference to Related Application

[0001] This application claims priority to and any benefit of U.S. provisional Application No. 62/480,897, filed on April 3, 2017, the entire contents of which are incorporated by reference in its entirety.

Field of the Invention

[0002] This disclosure relates to the field of rotary filling machines, and more particularly, to rotary filling machine having a sterile water seal at a rotary joint.

Background

[0003] Rotary filling machines are used for filling containers such as cans, bottles, cartons and the like with a wide variety of flowable materials such as baby food, juices, and other nutritional products. These machines usually have a rotary filling wheel with a number of filling assemblies spaced about its periphery. The containers are held in place beneath the filling assemblies and filled with the flowable materials.

[0004] In some applications, the process and final product must be aseptic and/or meet extended shelf life (ESL) requirements. In such applications, the machines must be designed to ensure that the bottled product is free of contamination caused by harmful bacteria, viruses, or other microorganisms.

Summary

[0005] The present application describes a rotary filling apparatus with a sterile water seal at a rotary joint. The rotary filling apparatus includes a non-rotating portion having a first fluid passage and a rotating portion having a second fluid passage. The first fluid passage includes an outlet end in fluid communication with an inlet end of the second fluid passage to form a rotary joint. An annular space surrounds the rotary joint. The annular space is in fluid communication with a source of sterile water capable of filling the annular space with sterile water during operation of the rotary filling apparatus.

[0006] The present application further also describes a rotary filling system that includes a rotary filling apparatus. The rotary filling apparatus has a non-rotating portion that includes a first fluid passage having an outlet end and a rotating portion that includes a second fluid passage having an inlet end. The inlet end of the rotating portion is in fluid communication with the outlet end of the non-rotating portion to form a rotary joint that is surrounded by an annular space. The rotary filling system may include a container having an inlet in fluid communication with the second fluid passage and a source of sterile water in fluid communication with the annular space such that the annular space is filled with sterile water during operation of the rotary filling apparatus.

[0007] The present application further describes a method of filling a container using a rotary filling apparatus. The method includes flowing a nutritional liquid from a first fluid passage in a non-rotating portion of the apparatus to a second fluid passage in a rotating portion of the apparatus. The first fluid passage is in fluid communication with the second fluid passage at an interface and the second fluid passage is in fluid communication with an inlet of the container. The method also includes surrounding an exterior surface of the interface with sterile water to form a sterile water seal around at the interface.

Brief Description of the Drawings

[0008] Features and advantages of the general inventive concepts will become apparent from the following detailed description made with reference to the accompanying drawings.

[0009] Figure 1 is a schematic representation of an exemplary embodiment of a rotary filling system.

[0010] Figure 2 is a section view of an exemplary embodiment of a rotary joint of the rotary filling system of Figure 1.

[0011] Figure 3 is a schematic representation of an exemplary embodiment of a source of sterile water for a rotary filling system. Detailed Description

[0012] Figure 1 is a schematic representation of a rotary filling system 100. The rotary filling system 100 is configured to fill a flowable material into one or more containers 101 under sterile conditions. The rotary filling system 100 may be configured in a variety of ways. The rotary filling system 100 may, for example, be a rotary filling system known in the art.

Examples of such filling machines are described, for example, in the following U.S. Pat. Nos. 7261199 B2 and 6,474,368 B2.

[0013] The flowable material may be any of a wide variety of materials, such as for example, baby food, juices, apple sauce, oils, nutritional drinks such as infant formulas, toddler or follow-on formulas, adult nutritional formulas, etc., or other suitable flowable materials. In one exemplary embodiment, the flowable material is a nutritional liquid containing at least one of protein, carbohydrate, and fat. In preferred exemplary embodiments, the nutritional liquid comprises protein, carbohydrate, and fat

[0014] The one or more containers may be configured in a variety of ways. Any container suitable for use with a rotary filling system may be used. For example, the size, shape, and material used for the container may vary in different embodiments of the system 100.

[0015] In the exemplary embodiment, the rotary filling system 100 is capable of filling containers under aseptic conditions. Alternatively, or in addition, the rotary filling system 100 is also capable of supporting extended shelf life (ESL) requirements. In the exemplary

embodiment, the rotary filling system 100 includes a container entry zone 102, a container preparation zone 104 that receives containers from the container entry zone 102, a container filling zone 106 that receives containers treated in the container preparation zone 104, a container capping/sealing zone 108 that caps and/or seals the filled containers, a cap sterilization zone 110 that provides sterilized caps to the capping/sealing zone 108, and a product outlet 112 where the filled, capped/sealed containers exit the rotary filling system 100. Other embodiments of the rotary filling system 100 may include less than the number of zones illustrated in Figure 1 or may include additional zones or sub-zones where additional functions may be performed.

[0016] The container preparation zone 104 may be configured in a variety of ways. Any configuration capable of sterilizing and maintaining the sterilization of the containers 101 and otherwise preparing the containers 101 to be filled may be used. For example, the container preparation zone 104 may be configured to sterilize the containers 101 by any suitable means. Suitable sterilization may occur by, for example, vaporizing a mixture comprised of H2O2 concentrate and sterile air and applying the resulting gaseous mixture to the exterior and interior of the containers 101. The container preparation zone 104 may also include a sterile water and/or sterile air rinsing station to rinse/dry any residual materials from the containers 101.

[0017] The capping/sealing zone 108 may be configured in a variety of ways. Any configuration capable of capping and/or sealing the containers 101 while maintaining sterilization of the containers 101 and the product within the containers 101 may be used.

[0018] The cap sterilization zone 110 may be configured in a variety of ways. Any configuration capable of sterilizing and maintaining the sterilization of the caps 111 of the containers 101 may be used. For example, the cap sterilization zone 110 may be configured to sterilize the caps 111 by any suitable means. Suitable sterilization may occur by, for example, vaporizing a mixture comprised of H2O2 concentrate and sterile air and applying the resulting gaseous mixture to the exterior and interior of the caps 111. The cap sterilization zone 110 may also include an air and/or water rinsing station to rinse/dry any residual materials from the caps 111.

[0019] The filling zone 106 may be configured in a variety of ways. Any configuration capable of filling the containers 101 with flowable material, such as for example, a nutritional liquid, and include a sterile water seal at a rotary joint may be used. In the illustrated embodiment, the filling zone 106 includes a rotary filling apparatus 120 in fluid communication with a source of flowable product 114 via a flowable product inlet 116.

[0020] Referring to Figure 2, the rotary filling apparatus 120 includes a rotary joint portion 200. The rotary joint portion 200 includes an interface 202 between a non-rotating portion 204 of the rotary filling apparatus 120 and a rotating portion 206 of the rotary filling apparatus 120 The rotating portion 206 is rotatably mounted relative to the non-rotating portion 204 in any suitable manner. The rotating portion 206 is configured to rotate during operation of the rotary filling apparatus 120. At times, however, the rotating portion 206 may not be rotating, such as during steam sterilization of the system 100 or during downtime. Thus, describing this portion configured to rotate when the rotary filling apparatus 120 is filling containers.

[0021] The non-rotating portion 204 is configured to transport the flowable material from the source of flowable material 114 to the rotating portion 206. The rotating portion 206 is configured to transport the flowable material to a plurality of filling assemblies 212. For example, the rotating portion 206 may include a rotary filling wheel (not shown) with the plurality of filling assemblies 212 spaced about its periphery, as is known in the art. Each of the plurality of filling assemblies 212 is in fluid communication with the opening (not shown) of one of the one or more containers 101 to fill the container with the flowable material.

[0022] The rotary joint portion 200 may be configured in a variety of ways. Any configuration that allows the flowable product to flow from the non-rotating portion 204 to the rotating portion 206 and may include a sterile water barrier surrounding the interface 202 may be used. In the illustrated embodiment, the non-rotating portion 204 defines a first fluid passage 220 and the rotating portion 206 defines a second fluid passage 222 in fluid communication with the first fluid passage 220.

[0023] The first fluid passage 220 extends from an inlet end 224 to an outlet end 225 along a central longitudinal axis A. The outlet end 225 includes a first wear member 228. The first wear member 228 may be configured in a variety of ways, including various shapes, sizes, and materials used in the first wear member 228. The first wear member 228 is designed to protect the outlet end 225 of the first fluid passage 220 and form a seal with a second wear member 268 positioned on the rotating portion 206. Suitable materials for the first wear member 228 include silicon carbide, polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK) and other suitable wear resistant materials. In the exemplary embodiment, the first wear member 228 comprises silicon carbide and is annular-shaped to form the terminal end of the outlet end 225 of the first fluid passage 220.

[0024] The first fluid passage 220 is at least partially defined by a head block 230 that extends from the inlet end 224 downward beyond the interface 202. The head block 230 defines an inlet port 232, an outlet port 234, and a flow passage 236 connecting the inlet port 232 to the outlet port 234. The inlet port 232 is configured to provide a fluid, such as sterile water, sterile steam, sterile air, or mixtures thereof, to the flow passage 236 and exiting the outlet port 234.

[0025] In the flow passage 236, between the inlet port 232 and the outlet port 234, is an annular space 240 that surrounds the interface 202. The annular space 240 may be configured in a variety of ways. Any space that surrounds the interface 220 and may be filled with a fluid to form a barrier around the interface 202 may be used.

[0026] In the exemplary embodiment, an open space 242 is formed in the flow passage 236 between the annular space 240 and the outlet port 234. The open space 242 houses one or more biasing members 244 for biasing the first wear member 228 against the second wear member 268. The open space 242 may be configured in a variety of ways. Any space that may house one or more biasing members 244 for biasing the first wear member 228 against the second wear member 268 to form a seal at the interface 202 may be used. In the exemplary embodiment, the open space 242 is annular and surrounds a sleeve 250 that defines a portion of the first fluid passage 220 upstream of the outlet end 225.

[0027] The one or more biasing members 244 may be configured in a variety of ways. Any one or more biasing members 244 capable of biasing the first wear member 228 against the second wear member 268 may be used and may be positioned in any suitable manner. In the exemplary embodiment, the one or more biasing members 244 include one or more springs positioned in the open space 242. For example, in certain exemplary embodiments, a plurality of springs are spaced about the periphery of the sleeve 250 and are configured so as to provide the appropriate force to bias the first wear member 228 against the second wear member 268. In other certain exemplary embodiments, a single spring may encircle the sleeve 250 to bias the first wear member 228 against the second wear member 268.

[0028] The sleeve 250 includes a first end 252 fixably attached to the head block 230 and a second end 254 that is fixably attached to a collar 256. The first wear member 228 is attached to the opposite side of the collar 256 than the second end 254. The collar 256 includes an engagement surface 258 facing the open space 242. The one or more biasing members 244 are positioned between the head block 230 and the engagement surface 258. The sleeve 250 is expandable such that the length of the sleeve 250 may be varied by expanding and contracting the sleeve along the axis A. The biasing members 244 bias the collar 256 toward the second wear member 228 such that the sleeve 250 expands and the first wear member 228 is biased against the second wear member 268. The sleeve 250 can be made of any suitable material. In one exemplary embodiment, the sleeve 250 includes polytetrafluoroethylene (PTFE).

[0029] The second fluid passage 222 extends from an inlet end 264 to an outlet end 265 along the central longitudinal axis A. The inlet end 264 of the second fluid passage 222 is in fluid communication with the outlet end 225 of the first fluid passage 220. For example, the inlet end 264 of the second fluid passage 222 may be aligned with the outlet end 225 of the first fluid passage 222 such that fluid exiting the outlet end 225 of the first fluid passage 222 flows into the inlet end 264 of the second fluid passage 222.

[0030] The inlet end 264 of the second fluid passage 222 includes the second wear member 268. The second wear member 268 may be configured in a variety of ways, including various shapes, sizes, and materials used in the second wear member 268. The second wear member 268 is designed to protect the inlet end 264 of the second fluid passage 222 and form a seal with the first wear member 228 of the first fluid passage 220. Suitable materials for the second wear member 268 include silicon carbide, Suitable materials for the first wear member 228 include silicon carbide, polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK) and other suitable wear resistant materials. In the exemplary embodiment, the second wear member 268 comprises silicon carbide and is annular-shaped to define the terminal end of the inlet end 264 of the second fluid passage 222. In some embodiments, the second wear member 268 and the first wear member 228 are the same, or similarly, shaped and comprise the same, or similar, materials.

[0031] As indicated above, the rotary filling system 100 may be used for filling containers under aseptic conditions and/or filling containers that meet extended shelf life (ESL)

requirements. Prior to operation of the rotary filling apparatus 120, the rotary filling apparatus 120 may undergo a sterilization process. In the illustrated example, during sterilization, steam is directed through the first and second fluid passages 220, 222 and the rotating portion 206 is not rotating.

[0032] In the exemplary embodiment, as part of a sterilization procedure, the inlet port 232 is placed in fluid communication with a source of sterile steam 290. The sterile steam is fed through the inlet port 232, through the flow passage 236, and into the annular space 240. The sterile steam fills the annular space 240 to sterilize the annular space and the exterior surface of the first wear member 228 and the second wear member 268 which form the interface 202.

[0033] In the illustrated embodiment, the sterile steam also flows through the flow passage 236 to the open space 242 to sterilize the open space 242 and the biasing members 244 contained therein. Having the open space 242 in the flow path of the flow passage 236 ensures that the open space 242 is treated in a similar manner to the annular space 240 with regard to

sterilization. Thus, the open space 242 does not present a risk of becoming contaminated and result in contamination of the filled containers. The outlet port 234 is in fluid communication with the open space 242, thus, after flowing through the open space 242, the sterile steam (and/or any condensate that forms) exits the rotary filling apparatus 120 via the outlet port 234.

[0034] During a transition period between the sterilization procedure and filling operations, (i.e., after sterilization, but prior to the filling operations beginning), the inlet port 232 is placed in fluid communication with a source of sterile air 294. The sterile air is fed through the inlet port 232, through the flow passage 236, and into the annular space 240 to fill the annular space 240 in a similar manner to the sterile steam during sterilization. The sterile air is provided at a suitable pressure and temperature to maintain sterilization of the rotary joint portion 200 and facilitate cooling of the rotary joint portion 200. In some exemplary embodiments, a positive sterile air pressure is maintained. For example, in some exemplary embodiments, the sterile air pressure is greater than 0.001 MPa (0.145 psi), greater 0.003 MPA (0.435 psi), or greater than 0.005 MPa (0.725 psi).

[0035] In some exemplary embodiments, the sterile air pressure is prevented from exceeding a sterile air pressure threshold. For example, to avoid potentially damaging equipment, a pressure bypass or relief valve (not shown) may be used to prevent the sterile air pressure from exceeding the sterile air pressure threshold. In some exemplary embodiments, the sterile air pressure threshold is 0.20 MPa (2.90 psi), 0.17 MPa (2.47 psi), or 0.15 MPa (2.18 psi).

[0036] The temperature of the sterile air may vary in different exemplary embodiments. In some exemplary embodiments, the sterile air is at ambient temperature, such as for example, in the range of about 20 deg C to about 25 deg . C (about 68 deg. F to about 77 deg. F). In other embodiments, however, the temperature of the sterile air may be greater than 25 deg. C or less than 20 deg. C.

[0037] During filling operations, the flowable material, from the source of flowable material 114, such as for example, a nutritional liquid, flows through the first fluid passage 220, past the interface 202, and into the second fluid passage 222. The inlet port 232 is placed in fluid communication with a source of sterile water 292. The sterile water is fed through the inlet port 232, through the flow passage 236, and into the annular space 240. The sterile water fills the annular space 240 to provide a barrier of sterile water within the annular space 240 that prevents contaminates from entering the first and second fluid passages 220, 222 via the interface 202. The sterile water within the annular space 240 is also a lower temperature than the steam that filled the annular space 240 during the sterilization process. In one exemplary embodiment, the sterile water is less than or equal to 30 degrees C. Some flowable materials, such as for example, nutritional liquids that contain proteins, carbohydrates, and fats, may form deposits within the first and second fluid passages 220, 222 when exposed to excess heat. Thus, using a barrier of sterile water, versus a higher temperature fluid such as sterile steam, reduces, or eliminates, the formation of deposits caused by overheating some flowable materials.

[0038] In some embodiments, the sterile water may be provided at least one of before, during, and after the flowable material flows through the first fluid passage 220, past the interface 202, and into the second fluid passage 222.

[0039] For example, in some exemplary embodiments, after sterilization with steam, but before flowable material is flowed through the first fluid passages 220, 222, the interface 202 is allowed to cool down, such as for example, by flowing sterile air into the annular space. Once cool, sterile water is flowed into the annular space 240. As further example, in some exemplary embodiments, prior to the rotating portion 206 beginning to rotate during the filling process, sterile water is flowed into the annular space 240.

[0040] As previously indicated, the open space 242 is treated in a similar manner to the annular space 240 with regard to steam sterilization. Likewise, sterile water flows through the flow passage 236 and into the open space 242 during operation of the rotary filling apparatus 120. The flow of sterile water through the open space 242 during operation provides additional protection against contamination originating from the open space 242. In particular, since the open space 242 is downstream from the annular space 240 with respect to the flow passage 236, the flow of sterile water through the open space 242 is in a direction away from the annular space 240.. The outlet port 234 is in fluid communication with the open space 242. Therefore, the sterile water, after flowing through the open space 242, exits the rotary filling apparatus 120 via the outlet port 234.

[0041] In the illustrated embodiment, the inlet port 232 is in fluid communication with the source of sterile steam 290 during sterilization, the source of sterile air during transition between sterilization and filling operations, and the source of sterile water 292 during filling operations. In other embodiments, however, the rotary filling apparatus 120 may have separate inlet ports and/or outlet ports for sterile steam, sterile air, and for sterile water.

[0042] The source of sterile steam 290, the source of sterile water 292, and the source of sterile air 294 may be independent sources that are connected to the inlet port 232, as shown in Figure 2. In an alternate, exemplary embodiment of a rotary filling system 300, a rotary filling apparatus 310 may be in fluid communication with a source of sterile water formed from a source of sterile steam. The source of sterile water may be formed from the source of sterile steam using any suitable method. Any apparatus capable of condensing sterile steam to sterile water may be used. For example, a heat exchanger or condenser may be utilized, along with a coolant, to cool and condense sterile steam to sterile water. As another example, a flash tank that flashes the sterile steam into sterile water upon entry into the tank without the use of a coolant may be used.

[0043] Referring to Figure 3, in the illustrated exemplary embodiment, a source of sterile steam 302 is in fluid communication with a heat exchanger 304. The heat exchanger 304 may be configured in variety of ways known in the art. Non-limiting examples of suitable heat exchanger configurations include a plate heat exchanger, a shell and tube heat exchanger, a plate and shell heat exchanger, and a plate and fin heat exchanger. The heat exchanger 304 may include a coolant inlet 306 and a coolant outlet 308. The heat exchanger 304 further includes a steam inlet 312 and a water outlet 314. The water outlet 314 of the heat exchanger 304 is in fluid communication with an inlet port 332 to the rotary filling apparatus 310 by a conduit 316.

[0044] The rotary filling system 300 may also include a steam bypass 318 that routes steam around the heat exchanger 304. A three-way valve 320 may be positioned upstream of the steam inlet 312. The three-way valve 320 is capable of routing steam either through the heat exchanger 304 or around the heat exchanger 304 via the steam bypass 318.

[0045] The steam bypass 318 is in fluid communication with an inlet port 332 to the rotary filling apparatus 310. In the illustrated embodiment, the steam bypass 318 connects to the conduit 316 at a location downstream of the heat exchanger 304. A check valve 322 may be positioned in the conduit 316 between the heat exchanger 304 and the junction between the conduit 316 and the steam bypass 318 to prevent steam from back-flowing into the heat exchanger 304.

[0046] In some embodiments, a source of sterile air 334 may be in fluid communication with the inlet port 332. In the illustrated embodiment, the source of sterile air 334 connects to the conduit 316 such that sterile air may flow into the conduit 316 and into the inlet port 332, during, for example the transition between sterilization and filling operations. In the illustrated embodiment, a shut-off valve 336 may be placed in the sterile air flow path between the conduit 316 and the source of sterile air 334 such that the flow of sterile air may be selected turned on or off.

[0047] In operation, as sterile steam flows into the heat exchanger 304, the coolant flowing through the heat exchanger 304 causes the sterile steam to condense into sterile water. The sterile water exits the heat exchanger 304 and flows into the inlet port 332 of the rotary filling apparatus 310 similar to the source of sterile water 292 in the rotary filling apparatus 120 of Figure 2. If sterile steam is desired, the three way valve 320 may bypass steam around the heat exchanger 304 and into the inlet port 332. If sterile air is desired the three way valve 320 may be shut-off and the shut-off valve 336 may be turned on.

[0048] While various inventive aspects, concepts, and features of the general inventive concepts are described and illustrated herein in the context of various exemplary embodiments, these various aspects, concepts, and features may be used in many alternative embodiments, either individually or in various combinations thereof. Unless expressly excluded herein all such combinations are intended to be within the scope of the general inventive concepts. Still further, while various alternative embodiments as to the various aspects, concepts, and features of the inventions (such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on) may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts, or features into additional embodiments and uses within the scope of the general inventive concepts even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated.

Moreover, while various aspects, features, and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts, and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.