EP3760576A1 - Filling machine for filling a liquid product into containers and method for controlling filling operations and / or cip processes on a filling machine - Google Patents

Abstract

A filling machine (1, 21) and a method for controlling 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 (5, 25). In addition to the short-circuit probes formed on the respective filling elements, the filling machine includes flow meters (7, 27) 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 filling process and in particular a container breakage when a predetermined permissible deviation of the actual flow rate from a target flow rate is exceeded.

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 calculate specific reference flows and / or reference flow curves over time for individual filling elements and / or different products and / or different cleaning agents.

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.

Figur 1

eine erste Ausführungsform der Füllmaschine; und

Figur 2

eine zweite bevorzugte Ausführungsform der Füllmaschine.

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

Figure 1

a first embodiment of the filling machine; and

Figure 2

a second preferred embodiment of the filling machine.

As the Figure 1 can be seen, 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, includes filling organs 4 with short-circuit probes 5 for ending filling processes on the individual containers 3 when / after reaching a Target filling level 6 of the product 2 in the containers 3.

Flow meters 7 are also individually assigned to the filling elements 4. The flow meters 7 are designed to measure a momentary actual flow rate 8 through the individual filling elements 4. The actual flow rate 8 can be measured in the product feed to the individual filling elements 4 and / or in the product paths running through the filling elements 4.

The actual flow rate 8 of the product 2 is preferably measured in supply lines 9 to the individual filling elements 4. The individual filling organs 4 are connected via the supply lines 9 to a product vessel 10 which, for example, is annular and, like the filling organs 4, is attached to a rotor 11 of the filling machine 1.

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

The filling elements 4 comprise a product valve 12 on the outlet side, which can release and prevent the discharge of the product 2 into the containers 3, which are attached to the filling element 4 from below, in a known manner.

A relief gas path 13 with a relief valve 13a and a tensioning gas path 14 with a tensioning gas valve 14a can also be seen on the filling element 4, which establish the connection to a relief channel 15 and tensioning gas channel 16 running centrally on the rotor 11 in a known manner.

A revolving lifting device 17 for lifting each of the containers 3 to the product valve 12 of the associated filling element 4 is also indicated schematically. This function is also known in principle and is therefore not explained in detail.

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

The evaluation unit 18 can, for example, be integrated in a control 19 for the filling elements 4 which is embodied on the filling machine 1. The controller 19 processes, for example, measurement signals from the short-circuit probes 5 and controls the product valves 12, relief valves 13a and tension gas valves 15a.

The filling machine 1 is probe-controlled. This means that the individual filling processes are terminated by the controller 19 as a function of a filling level measured by the short-circuit probes 5, that is to say when the target filling level 6 is reached.

In addition, the actual flow rate 8 of the product 2 through the individual filling elements 4 is continuously monitored with the aid of the flow meter 7. With the help of the actual flow rates 8 monitored in this way, the evaluation unit 18 can separately check for each filling element 4 whether the filling process currently running has a correct current actual flow rate 8 and / or a time course of the actual flow rate 8 or an impermissible one There is a deviation from this, for example due to a broken bottle or a leaky bottle mouth.

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

If the evaluation unit 18 calculates, for example, that the instantaneous actual flow rate 8 and / or its temporal course deviates in an impermissible manner from a characteristic reference flow rate and / or reference flow course, the impermissible filling process at the affected filling element 4 is terminated prematurely, in particular as quickly as possible .

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

Furthermore, the flow meter 7 can be used in CIP processes to monitor the instantaneous actual flow 8 of a CIP medium, that is to say a cleaning agent, sterilizing agent, rinsing agent or the like, and to integrate the measured actual flow 8, for example. As a result, an amount of the cleaning agent that has flowed through the respective filling element 4 can be determined cumulatively.

Thus, on the one hand, the amount of CIP medium that has flowed through the filling element 4 can be documented and the cleaning process for the individual filling element 4 can be ended in a targeted manner after a prescribed amount of the CIP medium has been reached for each filling element 4. The consumption of CIP media as a whole can thus be optimized.

The actual flow rates 8 measured at the individual filling elements 4 by means of the flow meter 7 can be stored in the evaluation unit 18 in order to calculate individual reference flow rates for the individual filling elements 4 therefrom. As a result, a normal behavior in the filling operation and / or during CIP can be characterized individually for the filling elements 4, for example in the form of individual setpoint characteristics.

Furthermore, statistical evaluations of the measured actual flow rates 8 are possible, for example the calculation of mean values and / or trends for individual filling elements 4. This allows the correctness of individual filling processes and / or CIP processes at the filling elements 4 to be monitored even more precisely and / or a Determine imminent malfunction of individual filling elements 4.

In addition, the reference flow rates and / or their chronological progressions can be stored product-specifically and / or format-specific for different filling processes in the evaluation unit 18 and activated by calling up appropriate product-specific and / or format-specific filling programs and / or CIP programs when production is changed.

Since a substantially uniform filling height of the container can be assumed in the case of probe-controlled filling, the actual flow rates 8 measured with the flow meters 7 and the product quantities calculated therefrom indicate whether the containers 3 are within a permissible range of their dimensional tolerance or in an impermissible manner differ. The flow measurement described in the product path thus also enables quality control of the containers 3 processed in the filling machine 1.

The ones in the Figure 1 The illustrated arrangement of the flow meter 7 on the respective supply line 9 to the individual filling elements 4 can be implemented with comparatively little technical effort and, if necessary, retrofitted to probe-controlled filling machines. For this purpose, the flow meters 7 are merely to be arranged at a suitable location, in particular in freely accessible sections of the supply lines 9, and the controller 19 is to be supplemented by the evaluation unit 18.

The supply lines 9 are preferably made from a plastic approved for filling liquid food, in particular from PTFE.

Supply lines 9 made of plastic are particularly suitable for flow measurement, since they do not hinder the function of electromagnetic / inductive flow meters 7. The Flow meters 7 can for example work inductively (IDM) or by determining mass flow (MDM).

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 Figure 2 shows schematically a filling machine 21 with a function that is basically identical to that described above. However, instead of the liquid product, a cleaning agent 22 or a similar CIP medium used in a CIP process is shown schematically. The filling machine 21 comprises a product path 23 on the outlet side, a filling element 24 surrounding it and a short-circuit probe 25 for ending individual filling processes after a target filling level 26 has been reached, which is in the Figure 2 is indicated only schematically (without container).

The filling machine 21 differs from the filling machine 1 described above essentially in the flow meters 27 integrated in the filling elements 24. These measure the actual flow rate 28 of the product or cleaning agent 22 in the area of the short-circuit probe 25.

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

The filling machine 21 further comprises an annular product vessel 29 to which the filling elements 24 are flanged without connecting lines running freely between them.

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

The filling machines 1, 21 can be used as follows:
Correct filling processes are automatically terminated by means of the short-circuit probes 5, 25 after the respective target height 6, 26 has been reached. In this way, all of the containers 3 are filled with the product 2 with an essentially identical filling height.

During the individual filling processes, the momentary actual flow rate 8, 28 of the product 2 to or through the filling elements 4, 24 is continuously monitored. The measured actual flow rates 8, 28 are continuously compared with at least one reference flow rate and / or a reference course of the flow rate. Any deviations in the actual flow rate 8, 28 that are determined in this regard are checked in the evaluation unit 18 for permissibility.

If, for example, an inadmissible deviation of the actual flow rate 8, 28 is determined, which is characteristic of a bottle breakage, the control 19 of the filling machine 1, 21 is instructed to automatically start the filling process of the filling element 4, 24 concerned by actuating the respective filling element 4, 24 existing product valve 12 prematurely and especially as early as possible. This makes it possible to prevent the product 2 from being delivered to a defective container 3 and thus being recorded as a product loss.

In CIP processes, a cleaning agent 22, sterilization agent or the like flows through the product path 23 and / or the supply line 9, the actual flow rate 8, 28 of which can also be monitored individually for the filling elements 4, 24 with the aid of the individual flow meters 7, 27 .

Here, the individual actual flow rates 8, 28 can be integrated, for example, and thus the amount of cleaning agent 22 that has flowed through the individual filling elements 4, 24 can be determined cumulatively. Likewise, the CIP processes for individual filling elements 4, 24 can be ended in a targeted manner as soon as a required minimum flow rate of cleaning agent 22 is reached at the respective filling element 4, 24 based on the measured actual flow rates 8, 28.

The criteria for assessing the admissibility of actual flows 8, 28 during filling processes and / or during CIP processes can be flexibly programmed for individual filling elements 4, 24 and / or products 2 and / or cleaning agents 22 and / or containers by means of electronic programming of the evaluation unit 18 3.

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 according to Claim 1, the flow meters (7) being arranged in / on supply lines (9) to the individual filling members (4). Filling machine according to Claim 1, further comprising an evaluation unit (18) for determining deviations in the current actual flow rates (8, 28) through the filling elements (4, 24) from at least one reference flow rate and in particular for assessing the permissibility of the deviations determined. Filling machine according to Claim 3, the evaluation unit (18) being 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 according to claim 3 and / or 4, further with a control (19) which is designed to prematurely prevent the product flow in the event of an impermissible deviation and in particular a container breakage determined based thereon individually for the filling element (4, 24) concerned. Filling machine according to one of Claims 3 to 5, the evaluation unit (18) being designed to store reference flow rates specific to the product (2) and / or individual filling elements (4, 24) and / or reference flow curves over time. Filling machine according to one of claims 3 to 6, wherein the evaluation unit (18) is designed to measure the measured actual flow rate (8, 28) for individual filling elements (4, 24) and / or different products (2) and / or different cleaning agents (22) to be stored individually and to be statistically evaluated 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. Method according to Claim 8, the actual flow rate (8) being measured in feed lines (9) to the individual filling elements (4). Method 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 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. Method according to Claim 11, in which individual filling processes are terminated prematurely by means of an electronic controller (19) in the event of an impermissible deviation characteristic of a container breakage. Method according to at least one of Claims 8 to 12, in which in CIP processes an amount of cleaning agent (22) that has flowed through individual filling elements (4, 24) is calculated from the actual flow rate (8, 28) measured in the process. Method according to claim 13, wherein the inflow of 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 electronic control (19) individually for the filling elements (4 , 24) is prevented.

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