GB2280669A

GB2280669A - Aseptic container filling system

Info

Publication number: GB2280669A
Application number: GB9315474A
Authority: GB
Inventors: Raymond William Sheppard
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-07-27
Filing date: 1993-07-27
Publication date: 1995-02-08
Anticipated expiration: 2013-07-27
Also published as: GB9315474D0; GB2280669B

Abstract

An aseptic filling system has a base frame formation 1 which can be designed inline, rotary or U-shaped and a counter pressure filling zone 7 where filling heads 9 direct metered volumes of the product into containers without foaming. Upstream of this filling zone is a container cleansing and flushing zone 2, a container closure zone 3 being provided downstream for aseptic sealing of product in the container. The filling and closure zones are housed in a clean air pressurised environment 5 and the cleansing and flushing zone has an independant clean air environment 4. Preferably the back pressure is maintained constant during filling. A cleaning in place system (14, Figure 4) charges and cleans the filling heads and associated piping which are fabricated in non-metal material having pores less than 0.22 microns. <IMAGE>

Description

ASEPTIC NEW FILLING SYSTEM This invention relates to an Aseptic New Filling System.

Aseptic filling systems are well known within the Food, Drink, Healthcare and Pharmaceutical industries, fabricated in stainless steel and supplied in the form of inline or rotary design, providing metered measurements of product to be deposited into bottles, cups or other containers and then sealed ready for use.

Aseptic filling offers producers the packaging process of their product at optimum condition and will maintain this condition for a period of time, extending product shelf life, without pasturisation, sterilisation, chilling or the use of product preservatives.

Aseptic filling provides a process to package amounts of edible products, that is free of harmful bacteria which would contaminate the products and reduce the shelf life.

Aseptic filling systems are, however, very expensive, being large in size and inflexible to product size change. In addition, the present aseptic system has difficulty in maintaining a bacteria free and clean environment, due to the fabrication material used, associated connections and the method of metering being positive displacement via a piston cylinder arrangement.

According to the present invention there is presented an Aseptic New Filling System (ANS) which is designed in a U-shape, rotary or inline formation comprising of a time pressure volume process.

This process enables measured amounts of product to be moved into containers under pre-set product pressure in a pre-set time, to provide accuracy of fill and to eliminate foaming of various products. The process incorporates a product back pressure. Once the product pressure and product back pressure has been set there will be a pressure differential which will be maintained automatically during the filling cycle, and non-fill time.

As this process provides for pressures above 14.71bs per sq.in to be maintained throughout its operation the process will maintain an aseptic filling condition, providing that inert gas is used as the media and all product contact areas are free of harmful bacteria.

To ensure a bacteria free environment a cleaning in place system is incorporated in this process. This system charges the time pressure volume process with cleaning, sterilisation and rinsing fluids at a pump pressure, which creates a scouring effect on all product contact areas. This cleaning in place system is carried out under a pressure greater that 14.71bs per sq.in, and once complete is automatically detached, and pressurised ready for filling, leaving the time pressure volume process free from product residue and bacteria.

The process allows any volume fill possible (single dose or multi-dose), dependent upon the relationship of pressure, pipework diameter and time. This relationship will be pre-set and controlled by computer and pneumatic systems using sensors, valves, buffer tanks, associated pipework and filling heads.

An arrester mechanism locates the container into the filling zone. The filling head(s) are an integral part of the time pressure volume process, which lowers onto the container(s) neck by pneumatic cylinders, sealing the container(s) by an inert material seated in the filling head neck. Once sealing has taken place, valves incorporated in the time pressure volume process will open, flushing and charging the container with the desired product back pressure prior to fill.

Once the product back pressure has been established product filling valves will open allowing the correct amount of product to enter into the container, by product pressure and fill time.

On completion of filling the fill valve closes and a gas valve will open, charging the head space with inert gas. This valve will then close and the filling head retracts allowing the container to move to the closure zone via a conveyor mechanism.

The filling and closure process is carried out under lamina flow and a pressurised clean air environment, maintaining aseptic conditions.

A sterile lamina air flow is sited at point of fill and closure. Adjacent and prior to the filling area is a container cleansing and flushing zone, to present ultra clean containers to the point of fill.

The filling and closure points will be housed in a clean air pressurised environment to ensure no airborne bacteria contaminates the product.

The cleansing and flushing zone will have an independent clean air environment.

The time pressure volume process will be fabricated in a non-metal material which has pores less than 0.22 microns.

This is the pore size used to filter sterile solutions, since the pores are so small there is no concern about microbes living in crevices on the material contact surfaces, thus eliminating possible harmful bacteria to form, providing aseptic conditions when the system has been cleaned in place and charged with an inert gas at a pressure above 14.71bs per sq.in.

A specific embodiment of the invention will now be described by way of example, with reference to the accompanying drawing in which: Figure 1 - shows in perspective the Aseptic New Filling System, combined with the container cleansing and flushing zone.

Figure 2 - illustrates the Aseptic New Filling System time pressure volume process, filling a container under product pressure and back pressure.

Figure 3 - shows the time pressure volume process completing container filling and charging the container head space with gas.

Figure 4 - shows the time pressure volume process combined with the clean in place system.

Referring to the drawing, the Aseptic New Filling System comprises a base frame formation (1) which can be designed inline, rotary or U-shape depending upon product flow desired, combined with a container cleansing and flushing zone (2) and a container closure zone (3).

In order to maintain aseptic conditions the Aseptic New Filling System, and the two zones, are provided with clean air environments (4) and sterile lamina flow system (5) as shown in Fig 1.

The method of container flow is by way of conveyor mechanisms (6) which enables containers to progress through the cleansing and flushing zone (2) and into the time pressure volume process (7), arrester control mechanisms (8) ensuring correct container location prior to filling via the filling heads (9). Once filling is complete the containers progress into the container closure zone (3), where the container closure mechanism (10) seals the containers as shown in Fig 1.

In order to provide aseptic conditions a time pressure volume process is used as shown in Fig 2. This process is a closed pressure system, comprising of a product metering pressure control (11) which meters accurate volumes of product within a set time, against a back pressure on filling. During filling a constant back pressure is maintained via the filling head (9) by a back pressure control unit (12), ensuring a pressure differential is maintained.

To maintain aseptic conditions after filling, and prior to closure, the time pressure volume process charges the head space (13) with inert gas as shown in Fig 3.

To ensure aseptic conditions are maintained after completing a product batch, and prior to the proceeding product batch, a cleaning in place system (14) charges and cleans the time pressure volume process under pressure, offering a bacteria free environment, as shown in Fig 4.

Claims

1. An Aseptic New Filling System (ANS) comprising a base frame formation, which can be designed inline, rotary or U-shape.

Incorporated into this system is a time pressure volume process, providing aseptic metered filling of product without foaming. Combined with this system is a container cleansing and flushing zone, ensuring ultra clean containers prior to filling, and a container closure zone aseptically sealing the product within the container.

The container cleansing and flushing zone, the Aseptic New Filling System and the container closure zone are contained in clean air environment and supplied with sterile lamina air at both the point of fill and the point of sealing, to maintain aseptic conditions throughout the complete operation.

2. An Aseptic New Filling System as claimed in Claim 1 wherein various design formations are used to suit different requirements.

3. An Aseptic New Filling System as claimed in Claim 1 or Claim 2 incorporates a time pressure volume process providing aseptic metered filling of product, without foaming, provided with non-metal material with pores less than 0.22 microns and a pressure always greater than 14.71bs per sq.in using inert gas as the product moving media.

4. An Aseptic New Filling System as claimed in Claim 2 or Claim 3 combines a container cleansing and flushing zone, providing means to remove debris and contaminated air from the container prior to filling.

5. An Aseptic New Filling System as claimed in Claim 4 combines a container closure zone, providing means to aseptically seal the product within the container.

6. An Aseptic New Filling System as claimed in any preceding claim, comprises the container cleansing and flushing zone, the time pressure volume process and the container closure zone which are provided with means of clean air and sterile lamina flow at point of fill and closure, to maintain aseptic conditions throughout the complete filling and sealing process.

7. An Aseptic New Filling System substantially as described herein with reference to Figures 1-4 of the accompanying drawings.