DE102019118096A1 - Filling machine for filling a liquid product into containers and a method for controlling filling processes and / or CIP processes on a filling machine - Google Patents

Abstract

A filling machine and a method for monitoring filling operations and / or CIP processes on a filling machine are described, the filling machine being designed to limit the filling level by means of a short-circuit probe. In addition to the short-circuit probes formed on the respective filling elements, the filling machine includes flow meters which are individually assigned to the filling elements for measuring a momentary actual flow through the individual filling elements. As a result, the correctness of filling processes and / or CIP processes can be assessed before a specified period of time or a specified machine angle has been run through for individual filling processes in order to minimize product losses in the event of a container break. Furthermore, CIP processes can be optimized and documented for individual filling elements.

Description

The invention relates to a filling machine for filling a liquid product into containers according to the preamble of claim 1 and a method for controlling filling operations and / or CIP processes according to the preamble of claim 8.

Filling machines of the generic type comprise filling members with short-circuit probes for ending filling processes after the product in the containers has reached a desired filling level.

A disadvantage of such filling machines is, for example, that individual filling processes in the event of a bottle break can only be ended after the machine angle range provided for filling and / or after a filling time provided for the filling process has elapsed. This means that it is only then possible to determine whether the absence of a short circuit in the area of the short circuit probe indicates an insufficient fill level and thus a broken bottle.

By the time the filling machine reaches the maximum filling angle and / or the maximum filling time has elapsed, a significant amount of product can therefore already be lost. Bottle breakage on such filling machines therefore leads to considerable product loss.

In addition, it would be desirable to be able to determine both the respective filling quantity at individual filling elements and an amount of a cleaning agent, sterilizing agent, rinsing agent or the like that has flowed through the individual filling elements during CIP processes.

There is therefore a need to improve filling machines and methods which are based on a fill level limitation by means of short-circuit probes with regard to at least one of the problems mentioned above.

The stated object is achieved with a filling machine according to claim 1. The filling machine is designed for filling a liquid product into containers and comprises filling elements with short-circuit probes for ending filling processes after the product has reached a desired filling level in the containers. According to the invention, the filling machine further comprises flow meters individually assigned to the filling elements for measuring a momentary actual flow through the individual filling elements.

This enables the flow rate through the individual filling elements to be determined both in filling operation and in CIP processes. It is possible to determine both the flow rate per time unit for any time intervals and the total amount of product or cleaning agent or sterilizing agent that has flowed through the individual filling elements for individual filling operations and / or CIP processes.

Monitoring the current actual flow also allows conclusions to be drawn about irregular filling processes, for example due to a broken bottle. A broken bottle leads to a characteristic change in the actual flow rate at the flow meter concerned, for example to a step-like increase in the actual flow rate.

The flow meters can be, for example, inductive flow meters (IDM), mass flow meters (MDM) and / or suitable mechanical flow meters (e.g. impeller meters).

It is also conceivable to determine the flow rate or the flow rate by means of differential pressure measurement and / or time measurement.

The flow meters are preferably arranged in / on supply lines to the individual filling elements. The flow meters can be arranged there in an easily accessible manner and, if necessary, retrofitted to existing filling machines with short-circuit probes for ending filling processes. However, the flow meters can also be arranged in / on the individual filling elements.

The feed lines are preferably made from a plastic, in particular from PTFE. Electrically insulating supply lines are suitable for different principles of flow measurement, in particular for inductive flow measurement. In addition, plastics make it possible to compensate for thermally induced stresses between assemblies made of different materials with relatively little construction effort.

The filling machine preferably further comprises an evaluation unit for determining deviations of the instantaneous actual flow rates through the filling elements from at least one reference flow, the evaluation unit being designed in particular to assess the permissibility of the determined deviation. The reference flow rate can, for example, be a setpoint range of the actual flow rate. In the case of an actual flow rate that deviates in a characteristic way from such a reference flow rate, it is possible, for example, to conclude that the container has broken.

The evaluation unit is then preferably designed to detect a faulty flow rate when a predefined permissible deviation of the actual flow rate from a target flow rate is exceeded Determine the filling process and in particular a broken container.

The deviation in the actual flow rate can be, for example, a significant increase in the actual flow rate above a reference flow rate / target flow rate in the sense of a threshold value. If the reference flow rate / target flow rate is exceeded, for example, over a predetermined period of time during the filling process, it is concluded that the container has broken or a similar leakage and thus that the filling process is faulty, i.e. improper.

The filling machine preferably includes a controller which is designed to prematurely prevent the product flow individually for the filling element concerned in the event of a faulty filling process / impermissible deviation, in particular in the event of a container breakage determined based thereon. Product losses due to container breakage or similar leaks on the outlet side can thus be minimized.

A premature termination of the filling process is to be understood as being terminated before the filling machine reaches a specified maximum filling angle and / or before the specified maximum filling time has elapsed.

The evaluation unit is preferably designed to store reference flows through the filling elements and / or reference flow curves over time through the filling elements, which are each specific for a certain product and / or specific for individual filling elements. This allows the function of individual filling elements and / or the presence of a broken bottle to be monitored particularly reliably.

Such specific reference flows and / or reference flow curves over time can be adapted on the basis of empirical values and / or measured values and / or after statistical evaluation of filling processes or the like in order to optimize the production process.

The evaluation unit is preferably designed to store the measured actual flow rate and to assign it to the assigned filling elements and / or the filled products and / or the cleaning agents used and to evaluate it statistically on this basis in order to determine for individual filling elements and / or different products and / or different cleaning agents to calculate specific reference flow rates and / or reference flow rates over time.

This enables an improved function control of the individual filling organs and an improved monitoring of the accompanying circumstances of individual filling processes. For example, a trend analysis of previously carried out filling processes enables a prediction of the course and / or the quality of the filling processes to be subsequently carried out with the individual filling processes. In addition, the quality and, in particular, the dimensional accuracy of the containers can be inferred from fluctuations in the actual filling quantity determined by flow measurement.

The object set is also achieved with a method according to claim 8. Accordingly, the method is used to control filling operations and / or processes for CIP (cleaning-in-place) on a filling machine with fill level limitation by means of short-circuit probes, in particular on a filling machine according to at least one of the embodiments described above. According to the invention, a momentary actual flow through the individual filling elements is monitored in addition to the filling level limitation.

The advantages described in relation to claim 1 can thus be achieved.

The actual flow rate is preferably measured in feed lines to the individual filling elements. This can be implemented comparatively easily in terms of apparatus and, if necessary, retrofitted to existing filling machines with fill level limitation.

Alternatively or additionally, the actual flow rate can be measured in the filling elements and then in particular in the area of the short-circuit probes.

A deviation of the instantaneous actual flow rate and / or its time profile from at least one reference flow rate and / or time reference flow profile is preferably calculated continuously. This allows you to determine deviations from reference values in real time and, if necessary, to draw conclusions about irregularities in the filling operation.

The calculated deviation is preferably assessed automatically with regard to its permissibility. This means that a permissible deviation is characteristic of a proper filling operation, while an impermissible deviation indicates a malfunction, in particular a broken bottle. A machine assessment of the reliability is carried out electronically based on comparison criteria in an assigned evaluation unit and / or control unit.

Preferably, individual filling processes are automatically terminated prematurely in the event of an impermissible deviation characteristic of a container breakage. This means that a detected impermissible deviation is evaluated in real time and output in a control signal to abort the respective filling process as promptly as possible and in any case before the proper end of the filling process. This way, product losses due to container breakage can be minimized.

The impermissible deviation is preferably calculated by comparing the actual flow rate and / or its time profile with at least one reference flow rate and / or time reference flow profile. Comparative criteria calculated in this way can be continuously optimized on the basis of data collected in previous filling processes on a specific filling element and, if necessary, adapted to changed production conditions. This allows the reliability to be optimized in the sense of weighing up potential false-positive results and false-negative results.

In CIP processes, an amount of a cleaning agent or similar CIP medium that has flowed through individual filling elements is calculated from the actual flow rate measured, for example cumulatively by integrating the measured actual flow rate. For example, a required flow rate can be logged.

The inflow of the cleaning agent to the individual filling elements is preferably prevented individually for the filling elements by means of electronic control after a prescribed amount of cleaning agent or similar CIP medium has been reached for each filling element. As a result, a flow rate required to achieve a specific quality criterion of the CIP processes can be precisely maintained and the consumption of CIP cleaning agent or similar CIP medium can be minimized overall.

• 1 eine erste Ausführungsform der Füllmaschine; und
• 2 eine zweite bevorzugte Ausführungsform der Füllmaschine.

Preferred embodiments of the invention are shown in the drawing. Show it:

• 1 a first embodiment of the filling machine; and
• 2 a second preferred embodiment of the filling machine.

As the 1 reveals includes the filling machine 1 for filling a liquid product 2 , such as a drink, in containers 3 such as bottles made of glass or plastic, filling organs 4th with short-circuit probes 5 to end filling processes on the individual containers 3 when / after reaching a target fill level 6th of the product 2 in the containers 3 .

The filling organs 4th are also flow meters 7th individually assigned. The flow meters 7th are for measuring a current actual flow rate 8th through the individual filling organs 4th educated. The actual flow 8th can in the product feed to the individual filling elements 4th and / or in the by the filling organs 4th running product paths can be measured.

The actual flow 8th of the product 2 is preferably used in supply lines 9 to the individual filling organs 4th measured. The individual filling organs 4th are via the supply lines 9 to a product boiler 10 connected, for example ring-shaped and how the filling organs 4th , on a rotor 11 the filling machine 1 is attached.

The rotor 11 is in the 1 indicated only schematically by dashed lines. The rotor 11 the filling machine 1 rotates continuously around a vertical axis of rotation in a conventional manner during the filling operation 11a . This is also due to the well-known mechanical functioning of the filling machine 1 only indicated schematically.

The filling organs 4th include a product outlet valve 12th that the dispensing of the product 2 in from below to the filling organ 4th sealed container 3 can release and prevent in a known manner.

At the filling organ 4th are also an example of a discharge gas path 13th with a relief valve 13a as well as a tensioning gas path 14th with a tensioning gas valve 14a to recognize the connection in a known way to a centrally located on the rotor 11 running relief channel 15th and tension gas duct 16 produce.

A revolving lifting device is also indicated schematically 17th to lift one of the containers 3 to the product valve 12th of the assigned filling organ 4th . This function is also known in principle and is therefore not explained in detail.

The filling machine 1 includes an electronic evaluation unit 18th for data processing with the flow meters 7th measured actual flow rates 8th of the product 2 .

The evaluation unit 18th can for example in one on the filling machine 1 trained control 19th for the filling organs 4th be integrated. The control 19th processes measurement signals from the short-circuit probes, for example 5 and controls the product valves 12th , Relief valves 13a and tension gas valves 15a .

The filling machine 1 is probe controlled. This means that the individual filling processes are dependent on one with the short-circuit probes 5 measured level, i.e. when the target level is reached 6th from the controller 19th completed.

In addition, the actual flow 8th of the product 2 through the individual filling organs 4th with the help of the flow meter 7th continuously monitored. With the help of the actual flow rate monitored in this way 8th can from the evaluation unit 18th for each filling organ 4th separately checked whether the filling process in progress has a correct current actual flow rate 8th and / or the course of the actual flow rate over time 8th or there is an impermissible deviation therefrom, for example due to a broken bottle or a leaky bottle mouth.

Such deviations are recorded by the evaluation unit 18th calculated and evaluated with regard to the reference values stored therein.

Calculates the evaluation unit 18th for example that the current actual flow rate 8th and / or its temporal course deviates in an inadmissible manner from a characteristic reference flow rate and / or reference flow course, then the inadmissible filling process is carried out on the filling element concerned 4th prematurely, especially canceled as soon as possible.

In other words, broken bottles and / or otherwise leaky containers 3 due to the flow measurement described can be recognized even with probe-controlled filling processes before the proper end of the individual filling processes is reached, i.e. before the filling machine has passed through the machine angle provided for the filling processes 1 and / or before the end of the filling time provided for the filling processes. This minimizes product losses due to irregular filling processes.

Furthermore, the flow meter 7th used in CIP processes to determine the current actual flow rate 8th a CIP medium, i.e. a cleaning agent, sterilizing agent, rinsing agent or the like, to monitor and the measured actual flow 8th for example to integrate. This allows one through the respective filling element 4th The amount of detergent that has flowed can be determined cumulatively.

Thus, on the one hand, the through the filling element 4th Document the amount of CIP medium that has flowed as well as the cleaning process for the individual filling element 4th after reaching one per filling element 4th terminate the prescribed amount of CIP medium in a targeted manner. The consumption of CIP media as a whole can thus be optimized.

The ones on the individual filling organs 4th by means of the flow meter 7th measured actual flow rates 8th can in the evaluation unit 18th be saved in order to generate individual reference flow rates for the individual filling organs 4th to calculate. This allows for the filling organs 4th individually characterize normal behavior in filling operation and / or during CIP, for example in the form of individual target characteristics.

There are also statistical evaluations of the measured actual flow rates 8th possible, for example the calculation of mean values and / or trends for individual filling elements 4th . This allows the correctness of individual filling processes and / or CIP processes on the filling elements 4th monitor even more precisely and / or an impending malfunction of individual filling organs 4th determine.

In addition, the reference flow rates and / or their chronological progressions can be product-specific and / or format-specific for different filling processes in the evaluation unit 18th saved and activated in the event of production changes by calling up appropriate product-specific and / or format-specific filling programs and / or CIP programs.

Since a substantially uniform filling height of the container can be assumed in the case of probe-controlled filling, let the flow meters 7th measured actual flow rates 8th and the product quantities calculated from this conclude whether the containers 3 lie within a permissible range of their dimensional tolerance or deviate from it in an impermissible manner. Thus, the described flow measurement in the product path also enables quality control of the filling machine 1 processed container 3 .

The ones in the 1 illustrated arrangement of the flow meter 7th on the respective supply line 9 to the individual filling organs 4th can be implemented with comparatively little technical effort and, if necessary, retrofitted to probe-controlled filling machines. For this purpose the flow meters are used 7th only at a suitable point, in particular in freely accessible sections of the supply lines 9 to arrange and control 19th through the evaluation unit 18th to complete.

The supply lines 9 are preferably made of a plastic approved for filling liquid food, especially PTFE.

Supply lines 9 made of plastic are particularly suitable for flow measurement because they function as electromagnetic / inductive flow meters 7th don't hinder. The flow meters 7th can work inductively (IDM) or by determining mass flow (MDM), for example.

Supply lines 9 made of plastic are also advantageous for connecting assemblies made of materials with different temperature-related expansion behavior, such as different steels, gray cast iron or the like.

The 2 shows schematically a filling machine 21st with basically the same function as described above. However, instead of the liquid product, there is a cleaning agent used in a CIP process 22nd or the like CIP medium shown schematically. The filling machine 21st includes a product path on the outlet side 23 , a filling organ surrounding this 24 and a short circuit probe 25th to end individual filling processes after reaching a target filling level 26th that are in the 2 is indicated only schematically (without container).

The filling machine 21st differs from the previously described filling machine 1 essentially through into the filling organs 24 integrated flow meter 27 . These measure the actual flow 28 of the product or detergent 22nd thus in the area of the short-circuit probe 25th .

The short circuit probe 25th can be in the area of the flow meter 27 for example a non-conductive section 25a include. This favors inductive flow measurement.

The filling machine 21st further comprises an annular product vessel 29 on which the filling organs 24 are flanged without freely running connecting lines in between.

The other functions of the filling machine 21st , especially the evaluation of the individual flow meters 27 measured actual flow rates 28 in the evaluation unit 18th and their connection to the controller 19th in principle correspond to those relating to the filling machine 1 functions described so that they are not described / shown again.

• Ordnungsgemäße Füllvorgänge werden mittels der Kurzschlusssonden 5, 25 nach Erreichen der jeweiligen Sollfühlhöhe 6, 26 automatisch beendet. Auf diese Weise werden sämtliche Behälter 3 mit im Wesentlichen identischer Füllhöhe mit dem Produkt 2 befüllt.

With the filling machines 1 , 21st can be worked as follows:

• Proper filling processes are detected by means of the short-circuit probes 5 , 25th after reaching the respective target height 6th , 26th ended automatically. In this way, all of the containers 3 with essentially the same fill level as the product 2 filled.

The current actual flow rate is continuously displayed during the individual filling processes 8th , 28 of the product 2 to or through the filling organs 4th , 24 supervised. The measured actual flow rates 8th , 28 are continuously compared with at least one reference flow and / or a reference course of the flow. Any deviations in the actual flow rate that may be determined in this regard 8th , 28 are in the evaluation unit 18th checked for admissibility.

For example, if there is an impermissible deviation in the actual flow rate 8th , 28 which is characteristic of a bottle breakage is determined by the control 19th the filling machine 1 , 21st instructed the filling process of the affected filling organ 4th , 24 automatically by actuating the on the respective filling element 4th , 24 existing product valve 12th to terminate early and in particular as early as possible. This can prevent the product 2 to a defective container 3 is released and is therefore recorded as product loss.

With CIP processes, the product path becomes 23 and / or the supply line 9 with a detergent 22nd , Sterilizing agent or the like flows through its actual flow rate 8th , 28 likewise with the help of the individual flow meters 7th , 27 individually for the filling organs 4th , 24 can be monitored.

The individual actual flow rates 8th , 28 for example integrated and thus through the individual filling organs 4th , 24 Amount of detergent that has flowed 22nd can be determined cumulatively. The CIP processes for individual filling elements can also be used 4th , 24 be terminated in a targeted manner as soon as a required minimum flow rate of the cleaning agent is reached 22nd on the respective filling element 4th , 24 based on the measured actual flow rates 8th , 28 is reached.

The criteria for assessing the admissibility of actual flows 8th , 28 during filling processes and / or during CIP processes, by means of electronic programming of the evaluation unit 18th flexible for individual filling organs 4th , 24 and / or products 2 and / or detergents 22nd and / or container 3 be determined.

Claims (14)

Filling machine (1, 21) for filling a liquid product (2) into a container (3), comprising filling elements (4, 24) with short-circuit probes (5, 25) for ending filling processes after the product (6, 16) has reached a desired filling level ( 2) in the containers (3), characterized by the filling elements (4, 24) individually assigned flow meters (7, 27) for measuring a momentary actual flow (8, 28) through the individual filling elements (4, 24). Filling machine after Claim 1 , wherein the flow meters (7) are arranged in / on supply lines (9) to the individual filling elements (4). Filling machine after Claim 1 , furthermore with an evaluation unit (18) for determining deviations of the instantaneous actual flow rates (8, 28) through the filling elements (4, 24) from at least one reference flow rate and in particular for assessing the admissibility of the deviations determined. Filling machine after Claim 3 , wherein the evaluation unit (18) is designed to detect a faulty filling process and in particular a container breakage when a predetermined permissible deviation of the actual flow rate (8, 28) from a target flow rate is exceeded. Filling machine after Claim 3 and / or 4, furthermore with a controller (19) which is designed to prematurely prevent the product flow for the affected filling element (4, 24) in the event of an impermissible deviation and in particular a container breakage determined based on this. Filling machine according to one of the Claims 3 to 5 , wherein the evaluation unit (18) is designed to store reference flow rates specific to the product (2) and / or individual filling elements (4, 24) and / or reference flow rates over time. Filling machine according to one of the Claims 3 to 6th , wherein the evaluation unit (18) is designed to individually and statistically store the measured actual flow rate (8, 28) for individual filling elements (4, 24) and / or different products (2) and / or different cleaning agents (22) evaluate in order to calculate specific reference flow rates and / or reference flow curves over time for individual filling elements (4, 24) and / or different products and / or different cleaning agents. A method for controlling filling processes and / or CIP processes on a filling machine (1, 21) with fill level limitation by means of a short-circuit probe (5, 25), in particular on a filling machine according to at least one of the preceding claims, characterized in that an instantaneous actual flow is monitored by the individual filling organs. Procedure according to Claim 8 , the actual flow rate (8) being measured in feed lines (9) to the individual filling elements (4). Procedure according to Claim 8 , the actual flow rate (28) being measured in the filling elements (24) and in particular in the area of the short-circuit probes (25). Method according to one of the Claims 8 to 10 , a deviation of the instantaneous actual flow rate (8, 28) from at least one stored reference flow rate and / or reference flow profile being continuously calculated by machine and, in particular, assessed for admissibility. Procedure according to Claim 11 , whereby individual filling processes are terminated prematurely by means of an electronic control (19) in the event of an impermissible deviation characteristic of a container breakage. Method according to at least one of the Claims 8 to 12th wherein, in the case of CIP processes, an amount of a cleaning agent (22) which has flowed through individual filling elements (4, 24) is calculated from the actual flow rate (8, 28) measured in the process. Procedure according to Claim 13 , the inflow of the cleaning agent (22) to individual filling elements (4, 24) after reaching a prescribed amount of cleaning agent (22) for each filling element (4, 24) by means of an electronic control (19) individually for the filling elements (4, 24) becomes.

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