Description:TECHNICAL FIELD
[0001] The present invention generally relates to a device and method for aseptic filling of packages.
BACKGROUND
[0002] Aseptic food packaging is a known method of packaging a food product. Conventionally, aseptic packaging requires special treatment and handling of the food product as well as all of the equipment that contacts the food product until it is secured inside of a hermetic container. Common methods employed in attaining this commercial sterility include steam, heated air, and chemicals. Chemicals are a common medium for this practice, and is harmful to a human body, especially if the material in a bag is a food, a beverage, or an enteral nutrition supply product, then harmful chemicals must be sufficiently removed in advance so that hydrogen peroxide of an amount exceeding a predetermined upper limit does not remain in the bag. However, removing harmful chemicals requires a process of air blowing and heating that takes a considerably long time. A large space and a long time are also required to remove harmful chemicals from a continuously fed film sheet by means of air blowing and heating. This leads to an increase in the size of the apparatus, as well as to degradation of a film that is caused by air-blowing and heating the film for a long time.
[0003] Therefore, there is a need of a device which overcomes the aforementioned problems.
SUMMARY
[0004] Embodiments of the present disclosure present technological improvements as solutions to one or more of the above-mentioned technical problems.
[0005] Before the present subject matter relating to device and method for aseptic filling of packages, it is to be understood that this application is not limited to the particular system described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the implementations or versions or embodiments only and is not intended to limit the scope of the present subject matter.
[0006] This summary is provided to introduce aspects related to device and method for aseptic filling of packages. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the present subject matter.
[0007] In one embodiment, a device for aseptic filling of packages, in particular flexible packages, the device includes, a container holding chamber; a filling nozzle; a sterilization unit; a package conveying system; a control unit configured to coordinate the filling process; a sealing mechanism for sealing filled packages; a feedback system for monitoring and adjusting the aseptic filling process.
[0008] In another embodiment, a method for aseptic filling of packages, the method includes the steps of sterilizing the container holding chamber and filling nozzle. The method includes the step of conveying packages to the filling nozzle. The method includes the step of filling the packages with a sterile substance. The method includes the step of monitoring aseptic conditions during filling. The method includes the step of adjusting the filling process based on real-time feedback. The method includes the step of sealing the filled packages.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0009] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference features and modules.
[0010] Figure 1 illustrates the overall configuration of an aseptic filling and packaging apparatus, according to an embodiment of the present invention.
[0011] Figure 2 illustrates a fitment feed device for feeding a plurality of fitments, and an apparatus for attaching each of the plurality of fitments to a film, according to an embodiment of the present invention.
[0012] Figure 3 illustrates an end view of an external fitment attached to the film, according to an embodiment of the present invention.
[0013] Figure 4 illustrates a vertical sectional view of the saddle bag packages, according to an embodiment of the present invention.
[0014] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative methods embodying the principles of the present disclosure. Similarly, it will be appreciated that any flow charts, flow diagrams, and the like represent various processes which may be substantially represented in computer readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
DETAILED DESCRIPTION
[0015] The invention will now be described with reference to the accompanying drawings and embodiments which do not limit the scope and ambit of the invention. The description provided is purely by way of example and illustration.
[0016] One or more embodiments are provided so as to thoroughly and fully convey the scope of the present invention to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present invention. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present invention. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
[0017] The terminology used, in the present invention, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present invention. As used in the present invention, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present invention is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
[0018] In one embodiment, a device for aseptic filling of packages, in particular flexible packages, the device includes, a container holding chamber; a filling nozzle; a sterilization unit; a package conveying system; a control unit configured to coordinate the filling process; a sealing mechanism for sealing filled packages; a feedback system for monitoring and adjusting the aseptic filling process.
[0019] In another implementation, the sterilization unit comprises one or more of the following: an ultraviolet (UV) sterilization module, a hydrogen peroxide vapor sterilization module, and a high-temperature sterilization module.
[0020] In another implementation, the filling nozzle includes a plurality of nozzles for simultaneously filling multiple packages.
[0021] In another implementation, a package orientation system is configured to ensure proper alignment of packages during filling.
[0022] In another implementation, the control unit utilizes sensors to detect contaminants and adjusts the filling process in real-time to maintain aseptic conditions.
[0023] In another implementation, the sealing mechanism is adapted to seal packages with various packaging materials and sizes.
[0024] In another embodiment, a method for aseptic filling of packages, the method includes the steps of sterilizing the container holding chamber and filling nozzle. The method includes the step of conveying packages to the filling nozzle. The method includes the step of filling the packages with a sterile substance. The method includes the step of monitoring aseptic conditions during filling. The method includes the step of adjusting the filling process based on real-time feedback. The method includes the step of sealing the filled packages.
[0025] In another implementation, the method includes the step of sterilizing includes subjecting the container holding chamber and filling nozzle to a sterilization method selected from the group consisting of ultraviolet (UV) sterilization, hydrogen peroxide vapor sterilization, and high-temperature sterilization.
[0026] In another implementation, the method includes the step of orienting packages to ensure proper alignment during filling.
[0027] In another implementation, the method includes the step of monitoring aseptic conditions, includes the use of sensors to detect contaminants in the filling environment.
[0028] Figure 1 illustrates the overall configuration of an aseptic filling and packaging apparatus.
[0029] In an embodiment, aseptic filling and packaging apparatus 11 according to the present embodiment has film supplying device 12 and spout attaching device 13. Film supplying device 12 supplies a strip-shaped continuous film (hereinafter, referred to as film sheet F) that is not in an aseptic environment (i.e., normally, having microbes thereon). Although not illustrated, film supplying device 12 holds a roll of film sheet F that is being supplied, as well as a roll of waiting film sheet F, and includes a mechanism that can switch to the waiting film sheet F without stopping the operation of aseptic filling and packaging apparatus 11 when film sheet F that is being supplied is consumed. Spout attaching device 13 attaches spout 2 to a side edge of film sheet F that is being supplied. In order to enhance the effect of sterilizing film sheet F, it is necessary to raise the concentration of gaseous hydrogen peroxide in sterilization chamber 15, and to do so, it is desirable to prevent the condensation of gaseous hydrogen peroxide. If the surface temperature of film sheet F is low, then the gaseous hydrogen peroxide partially condenses on and adheres to the surface of the film. This causes the gaseous hydrogen peroxide to be partially lost in sterilization chamber 15, and prevents an increase of the concentration of gaseous hydrogen peroxide. It is also difficult to remove the hydrogen peroxide that adheres to the surface of the film in ventilation chamber 16, which will be described later. Therefore, electric heater 14 a is provided on a wall of antechamber 14 in order to preheat film sheet F before it enters sterilization chamber 15. Electric heater 14 a may be provided upstream of antechamber 14 or may be omitted, depending on the case.
[0030] In an embodiment, sterilization chamber 15 sterilizes film sheet F having spout 2 before it is formed into a bag. Spout 2 and film sheet F are sterilized at the same time. Sterilization chamber 15 is filled with gaseous hydrogen peroxide. The concentration of the gaseous hydrogen peroxide is set in advance at a level high enough to sufficiently kill microbes, such as botulinus. In sterilization chamber 15, a plurality of upper rollers 15 a and a plurality of lower rollers 15 b are arranged alternately, and film sheet F is conveyed in sterilization chamber 15 along a winding path. This can reduce the volume of sterilization chamber 15, while securing an enough time for sterilization. Spray pipe 15 c for gaseous hydrogen peroxide is provided in the upper part of sterilization chamber 15, and can disperse gaseous hydrogen peroxide uniformly in sterilization chamber 15. Sterilization chamber 15 is kept at a positive pressure relative to the outside of aseptic filling and packaging apparatus 11 in order to prevent dust from entering sterilization chamber 15. Sterilization chamber 15 is connected to supplying device 24 via first line L1. Supplying device 24 comprises of a gaseous hydrogen peroxide supplier, an air supplier and mixer 27 that mixes the gaseous hydrogen peroxide with the air. The air supplier has a second fan F2 that supplies outside air, electric heater 25 and HEPA filter 26, all of which are provided on fourth line L4. Fourth line L4 branches from third line L3 on the outlet side of medium efficiency particulate air filter 31 so that dehumidified clean air can be supplied. Electric heater 25 raises the temperature of the outside air, and thereby prevents condensation of the gaseous hydrogen peroxide that is to be mixed with the outside air.
[0031] Filling and packaging chamber 17 has filling device 35 that fills plastic film packaging bag 1 with a material. Filling device 35 has injection pipe 35 a that extends in the film that is formed into a tubular shape. Filling and packaging chamber 17 has a sealing device that seals plastic film packaging bag 1 that is filled with a material. The sealing mechanism 37 may further include a cutter (not illustrated) that cuts the film along lateral seal 5 in the width direction. By cutting the film along lateral seal 5, separate plastic film packaging bags 1 are obtained.
[0032] Figure 2 illustrates a fitment feed device for feeding a plurality of fitments, and an apparatus for attaching each of the plurality of fitments to a film.
[0033] In an embodiment, film 204 is advanced past guide roller 214, and into adjacent alignment with the lead fitment 202, the film disposed between fitment 202 and an attaching device such as a heat sealer 220. Thus, the film 204 passes between the attaching device and the lead fitment. When each fitment is appropriately positioned relative to and adjacent the film, the attaching device is activated to press and seal the film to one planar surface of the fitment. Guiding device 216 acts as a sealing anvil in facilitating attachment of the film to the fitment. After the fitment has been attached to the film, the film is advanced toward a sterilizing assembly to be described further below. A constant heated seal head can be used to effect attachment of the film to the fitment. Fitments are attached at pre-determined intervals to the film, the gap between sequential fitments pre-determined based on the desired length of each pouch made in the downstream Vertical form/fill/seal (VFFS) apparatus, and the ultimate desired length of each final aseptic package.
[0034] Fitments 202 are put into a hopper 210. These fitments 202 are then run through an orienter 212 to align the fitments in an appropriate direction. Fitments 202 are fed, for example in individual sequence, by suitable motive force, or gravity, to a guiding device 44 that aligns each fitment adjacent film 204 advancing from film unwind device.
[0035] Figure 3 illustrates an end view of an external fitment attached to the film.
[0036] In an embodiment, the apparatus 208 only partially attaches each of the plurality of fitments to the film. There are two regions of attachment 304 of film 204 to fitment 302. Attachment can be at any suitable location on the fitment, and can be more specifically at any suitable location on the annular ring. In one embodiment, the two regions of attachment define a line parallel to the direction of travel of the film, this embodiment proving particularly useful during the drying process described further herein. In another embodiment, only one region of attachment can be present; alternatively, more than two regions of attachment can be present. In each embodiment, a portion of the fitment in contact with the film, or a portion of the surface of the annular ring adjacent the film, is not sealed to the film at this stage of the system and process.
[0037] Figure 4 illustrates a vertical sectional view of the saddle bag packages.
[0038] In an embodiment, the packages 400 includes a top panel 408 and a bottom panel 410. The top panel 408 of each bag is permanently sealed to the bottom panel 410 along its two side edges, respectively, and along its bottom edge 414. In accordance with one preferred embodiment of this invention, the top edge 406 of each panel 408 is releasably secured to the portion of the intermediate section contiguous with the portion of the bottom panel directly underlying the top panel. To that end, an adhesive tape strip 404 extends across and is adhesively secured to the entire length of top edge of one of the bags while also extending across and being adhesively secured to the contiguous portion of the intermediate section 402. In a similar manner another adhesive strip 404 extends across and is adhesively secured to the entire length of top edge of the other of the bags and also extends across and is adhesively secured to the contiguous portion of the intermediate section 402. The presence of the tape strips 38 across each of the bags of each saddle package 412 ensures that the hollow interior 412 of each of those bags remains hermetically sealed and sterile. The fabrication of the supply of precursor packages 400 can be accomplished using any suitable flexible package making technique and equipment involving the sterilization and hermetic sealing of the bags or pouches 412A and 412B.
[0039] The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the substance of the invention may occur to person skilled in the art, the invention should be construed to include everything within the scope of the invention.
, Claims:We claim:
1. A device for aseptic filling of packages comprising:
a. a container holding chamber;
b. a filling nozzle;
c. a sterilization unit;
d. a package conveying system;
e. a control unit configured to coordinate the filling process;
f. a sealing mechanism for sealing filled packages; and
g. a feedback system for monitoring and adjusting the aseptic filling process.
2. The device of claim 1, wherein the sterilization unit comprises one or more of the following: an ultraviolet (UV) sterilization module, a hydrogen peroxide vapor sterilization module, and a high-temperature sterilization module.
3. The device of claim 1, wherein the filling nozzle includes a plurality of nozzles for simultaneously filling multiple packages.
4. The device of claim 1, further comprising a package orientation system configured to ensure proper alignment of packages during filling.
5. The device of claim 1, wherein the control unit utilizes sensors to detect contaminants and adjusts the filling process in real-time to maintain aseptic conditions.
6. The device of claim 1, wherein the sealing mechanism is adapted to seal packages with various packaging materials and sizes.
Method Claims:
7. A method for aseptic filling of packages comprising the steps of:
a. sterilizing the container holding chamber and filling nozzle;
b. conveying packages to the filling nozzle;
c. filling the packages with a sterile substance;
d. monitoring aseptic conditions during filling;
e. adjusting the filling process based on real-time feedback; and
f. sealing the filled packages.
8. The method of claim 7, wherein the step of sterilizing includes subjecting the container holding chamber and filling nozzle to a sterilization method selected from the group consisting of ultraviolet (UV) sterilization, hydrogen peroxide vapor sterilization, and high-temperature sterilization.
9. The method of claim 7, further comprising the step of orienting packages to ensure proper alignment during filling.
10. The method of claim 7, wherein the step of monitoring aseptic conditions includes the use of sensors to detect contaminants in the filling environment.