IES68516B2 - A sampling device and method - Google Patents

Abstract

The invention concerns a sampling device for extracting a sample from a sealed bulk product, for example, a solid product such as a block of cheese, or a granular product such as milk powder. The device comprising a sample extraction means, which may be a trier or tube (2, 30, 52) insertable through a seal (25, 66) into the bulk product (10, 60) for extraction of the sample (11, 61). The sample extraction means (2, 30, 52) is contained within a sealed air-tight envelope (4, 54) and has sealing means (5) for connecting the encapsulating means (4, 54) to the seal (25, 66) of the bulk product (10, 60). The sample is extracted into the envelope (4, 54), and the envelope is then heat-sealed such that the sealing means (5) reseals the bulk product after extraction of the sample (11, 61). The sample is thus removed in an aseptic manner without permitting contamination of the bulk product. The device for extracting the sample from the bulk product (10, 60) may comprise a trier (30) which has a hollow tubular body (32) and a pointed end (34). A wall (33) defining the tubular body (32) of the trier (30) has at least one, but preferably two, lines of weakness extending axially of the trier (30) by means of which the trier (30) may be broken open to release the sample.

Description

The present invention relates to a sampling device. In particular, the invention relates to a device for extracting samples from bulk quantities of foodstuffs, pharmaceuticals and the like, which may be in solid, granular, or fluid form. For example, the device of the invention is intended for extracting samples for testing from foodstuffs such as cheese, butter, icecream, dehydrated vegetable products, milk powders and the like.

Background of the Invention Quality sampling of manufactured products has become routine in the food and pharmaceutical industries. Routine samples of the product may be required to test for various quality parameters.

For example, in the cheese industry it is common practice to periodically sample blocks of cheese to test for flavour and texture of the cheese. The conventional method of doing this is to remove a plug or finger of cheese from the cheese block by means of a sampling tool called a trier. A trier is a tool having a handle and a blade. The blade has a concave surface such that when inserted in the cheese block and rotated, it cuts a cylindrical plug from the cheese block, which is removed from the cheese block with the blade.

Other sampling devices for foodstuffs are known. FR 252770 discloses a sampling probe for sugar beet which consists of a sheath having a quadrangular section, preferably square, which can extend vertically. The upper part of the probe is attached to a lifting jack. The lower part is equipped with two shutters which lie on either S685 16 side of the longitudinal plane of symmetry. The shutters are pivotally mounted, with the aid of a control coupling around the sheath, such that they can close or open to cover or uncover an orifice in the lower end of the sheath.

FR 2442441 discloses a device for extracting a plug of a product by a hollow sleeve which cuts through the product. The plug is cut with the required section to obtain a better sample than by cutting and storing all the products during its travel. A square section sleeve has sides with cutting edges. Flat shutters are positioned to pivot to close the lower end of the sleeve. Spaces in opposite faces of the sleeve house the shutters when they are open.

US 3978733A discloses a rotating coring tube which removes a . sample from a mass of sugar cane by advancing the rotating coring tube into the mass and then ejecting the core sample from the cutter tube. The apparatus includes a single ram which on its first stroke advances the coring tube in unison with the ejector piston and then retracts to remove the core from the sugar cane mass. On its second stroke the coring tube is held stationary while only the piston is advanced to eject the core from the coring tube. This invention relates in particular to sampling sugar cane mass.

One of the problems associated with known sampling devices is that their use may result in the contamination of the bulk food product from which the sample is taken. For example, the taking of the sample may result in the breaking of a seal where the product is a sealed product resulting in microbiological or other contamination of the product. The environment of the product is then compromised. This is a particular problem in the cheese industry, but is not confined to that industry.

For example, cheddar cheese may be produced on a batch system of 2,000 litres. This is the equivalent of 100x20kg blocks of cheddar. For every batch of cheddar cheese produced there is 1x20kg block which is designated as the sample block. Cheddar cheese is a live product; it will undergo chemical and compositional changes over time which will affect both the flavour and texture of the cheese. In general, the quality and value of the cheese increases with time.

Cheddar cheese can be sold at ages varying from 1 week old to 18 months old. This will depend on how the quality of the cheese develops on storage, and the market requirements at any given time. In order to monitor how the cheddar is performing the sample block is inspected approximately every 6 weeks. This involves boring the cheddar block and removing a sample or finger” of cheese. This sample is then graded using conventional methods of cheese grading. The sample block is not sold with the bulk cheese. As a result of the necessity of grading the sample block may have up to 10 bore holes, the average would probably be 2 or 3. These bore holes become mouldy over time due to introduction of air. There is spoilage of the cheese product around the area of the bore holes due to contamination on sampling by use of an improperly/non sterile sampler, and/or because of loss of integrity of the seal encapsulating the cheese. The cheese block requires cleaning before sale by removal of spoiled portions. Cleaning can result in 2.5 - 5.0% loss in weight. Contamination of sample blocks involves cost and loss of product because of: (i) the cleaning costs involved, (ii) the weight loss of product during cleaning, and (iii) the condition of the cleaned block limits its end use These problems are not only encountered with cheese products but also with other aseptically/atmospherically sealed products which require sampling after sealing. Weight losses can result in as much as 8 - 10% loss of the sale value in the case of cheeses.

The prior art sampling devices discussed above do not provide a method of retrieving an aseptic sample from a product. In particular they do not relate to sampling of products which have been aseptical ly/atmospherically sealed and which must be sampled after (aseptic/atmospheric) sealing has taken place. Known sample devices can be used to pierce the aseptically sealed product and retrieve a sample. The sampler used is exposed to the air and is not protected from contact with various possible contamination sources. Also the product sample taken is exposed to the air and it is thus subject to contamination. Furthermore, the mass of product from which the sample is taken is contaminated because of exposure to the air. The integrity of the seal is disrupted which also leads to further contamination due to continued exposure of the product to air.

Resealing the mass of the product is necessary to restore defined packaging conditions. Because of contamination of the product it may be necessary to discard the complete portion of product sampled, or at least the amount of product contaminated during or subsequent to sampling.

Object of the Invention It is an object of the invention to overcome the disadvantages of known sampling devices and to provide a sampling device and method which allows an aseptic sample to be taken. Furthermore the invention seeks to provide a method of disrupting the integrity of a seal on a sealed product during a sampling process without loss of the sealed environment of the product. It is also an object of the invention to provide for the re-sealing of the product during the sampling process.

Summary of the Invention: The present invention provides a sampling device for extracting a sample from a sealed bulk product comprising a sample extraction means insertable through the product seal into the bulk product for extraction of the sample and a receiving means for receiving and containing the extracted sample, characterised in that the sample extraction means is contained within a sealed air-tight encapsulating means and has connecting means for connecting the encapsulating means to the seal of the bulk product, whereby said connecting means may be used to reseal the bulk product after extraction of the sample.

Preferably the encapsulating means comprises an air-tight envelope comprised of a flexible membrane within which the sample extraction means is located, and means being provided for sealing the envelope after extraction of the sample.

In a preferred embodiment the receiving means for containing the extracted sample is a portion of the envelope.

In an alternative embodiment the receiving means for containing the extracted sample is a container.

The sample extraction means may comprise a hollow cylindrical tube or a concave part-circular shaped blade.

In a preferred, embodiment the sealing means comprises a one-sided adhesive tape preferably the non-adhesive side is sealed to the exterior of the envelope at that area of the envelope which is directly below the extraction means, and suitably the one-sided adhesive tape has a protecting cover on the adhesive layer of the tape.

Alternatively the environment within the envelope comprises an inert gas or a defined atmosphere. The inert gas or defined atmosphere comprising a gas or mixture of gases which will not cause the product quality to deteriorate substantially over a defined period.

Preferably the sampling device is aseptically sterilised or manufactured in a sterile manner. Suitably the sampling device is sterilised by exposure to a sufficient dose of gamma radiation.

The invention further provides a method of aseptically removing a sample from a bulk product by means of a sampling device as described above, characterised in that the method comprises the steps of: (i) bonding the sealing means of the encapsulating means to provide an air-tight seal between the encapsulating membrane and the wrapping enclosing the bulk product (ii) piercing the sealing means or a layer thereof with the sampling means and inserting the sampling means through the product wrapping and into the bulk product (iii) removing a sample of the bulk product, and the sampling means into the receiving means, and (iv) re-sealing the wrapping of the bulk product by means of the sealing means and the encapsulating means.

Brief description of the drawings While the present invention is susceptible of embodiment in many forms, there is shown in the drawings and will hereinafter be described two presently preferred embodiments with the understanding that the present specification is to be considered as an exemplification of the invention, which is not intended to limit the invention to the specific embodiments illustrated. In the drawings: Figure 1 is an elevation of the first embodiment of a sampling device of the invention; Figure 2 is a cross-section of the line A - A of Figure 1; Figure 3 is a cross-section of the line B - B of Figure 1; Figure 4 is a plan view of the device of Figure 1; Figure 5 is an elevation of the sealing means of the device of Figure 1; Figure 6 is a cross-section of the sealing means of the device of Figure 1; Figure 7 is an elevation of the device of Figure 4 with handle attached, applied to a block of cheese; Figure 8 is an elevation of the device of Figure 7 partly inserted in a block of cheese; Figure 9 shows the device of Figure 7, with sample attached,. withdrawn from a block of cheese; Figures 10 and 11 illustrate the sealing of the removed sample and block of cheese; / Figure 12 is an elevation of a second embodiment of a sampling device / . of the invention; Figure 13 is a plan view of the device of Figure 12; Figure 14 is an elevation of the device of Figure 12 applied to the underside of a container containing the product to be sampled.

Figure 15 is a view similar to Figure 14 showing the extraction of the sample; Figure 16 illustrates the sealing of the container and sample.

Detailed Description of the preferred embodiments A first embodiment of a sampling device of the invention is illustrated in Figures 1 to 11. This device is particularly suitable for extracting samples from hard or semi-soft products, for example cheese blocks, and its operation will be described for this purpose.

Refering to Figures 1 to 6, the sampling device (1) comprises a sampling blade (2), a handle (3), an encapsulating envelope (4), a sealing means (5) and a cap (6). The sampling blade (2) is a trier, having a concave surface in cross section, on the line B-B (Figure 3), preferably a part circular cross section. The sampling blade (2) is joined to the cap (6). The cap (6) is detachably connected to the handle (3). Preferably the handle (3) consists of a strong rigid material, for example heavy duty polypropylene and the like. The cap (6) and handle (3) have interlocking complementary connections (7) which allow the handle (3) to be removed from the cap (6).

The connections (7) comprise a hollow boss (14) fitted to the end of the handle (3). The boss (14) has a narrow rectangular opening (15). A complementary spigot (16.) is provided on the cap (6). The spigot (16) is substantially T-shaped and has a rectangular head (17) which fits through the opening (15). On inserting the spigot (16) in the boss (14) and turning the handle (3), the handle is locked onto the cap (6). The sampling blade (2) preferably has sharpened edges (8) and a tapered point (9). Preferably the sampling blade (2) consists of a suitable rigid material which can be sterilised. For sampling a hard solid product the sampling blade (2) may comprise a rigid disposable material, preferably comprising a biodegradable material. In particular a durable rigid plastic material may be used for sampling cheeses. In particular the sampling device (1) may be disposable, the handle (3) being detachable and reusable.

The sampling blade (2) may be suitably shaped so as to retain the sample taken from the product where the sample is a 'core' or finger1 or 'plug' of the product. The cap (6) is rigidly fixed to the sampling blade (2) so that when the handle (3) is attached to the cap (6) by the connections (7), the handle (3) controls motion of the sampling blade (2).

The cap (6) may comprise a rigid plastic material which may be sealed via an airtight bond to an envelope (4) e.g. by heat sealing.

The envelope (4) comprises a durable flexible film, suitably a transparent, non-permeable, polymeric film. The envelope (4) encapsulates the sampling blade (2). Suitably the envelope (4) extends from the cap (6) in dimensions sufficient to allow ease of movement of the sampling blade (2) within the envelope (4) and independently of the envelope (4).

Referring to Figures 5 and 6, the sealing means (5) is attached to the envelope (4) by an airtight bond. The sealing means (5) comprises a base pad (20) which is bonded, for example, by heat sealing, to the lower end of the envelope (4), remote from the handle (3). The base pad (20) comprises an adhesive tape (21) having an adhesive layer (22) on the surface remote from the envelope (4). A removable protective covering film (23), which may be a polymeric film, protects the adhesive layer (22) when not in use. The peripheral edges of the adhesive tape (21) are protected by a rigid backing (24) of flexible polyethylene. The rigid backing (24) comprises an aperture (27). The aperture (27) is large enough to accommodate the sampling blade (2).

The envelope (4) is sealed in an airtight manner to the rigid backing (24) between the circumference of the aperture (17) and the edges of the rigid backing (24).

The environment within the envelope (4) may be suitably adapted to meet different requirements. Preferably the envelope (4) contains an atmosphere of a suitable gas in particular an inert gas (e.g. carbon dioxide, nitrogen or any 'noble gas'). However the envelope may contain any atmosphere suitable to the product being sampled i.e. an atmosphere of a gas or mixture of gases which will not substantially affect the quality of the product over a defined period.

The sampling device (1) may be manufactured in sterile form or may be sterilised e.g. by exposure to a sufficient amount of gamma radiation.

A method of taking a sample using the sampling device (1) of the present invention described below with reference to Figures 7 to 11 of the drawings (note in Figures 10 and 11 the handle (3) is not shown).

Firstly, the protective covering (23) is removed from the single-sided adhesive tape (21) and the exposed adhesive surface (22) is attached to the wrapping containing the product (10). In the case of cheese the wrapping is typically a plastics wrapping film (25). The adhesive tape (21) forms an air-tight bond with the wrapping film (25). The sampling blade (2) is then pushed down and forced through the adhesive tape (21) and into the product (10), piercing the wrapping film (25). Optionally a rotating or oscillating movement can be used to help insertion of the sampling blade (2) in the product (10). The presence of inert gas within the envelope (4) maintains the membrane forming the envelope (4) away from the blade (2).

Figure 8 shows the sampling blade (2) inserted in the product (10), in this case a cheese block. As shown in Figure 9 the sampling blade, with a plug or finger or core (11) of cheese contained within the sampling blade is withdrawn from the block of cheese (10), to leave a cavity (26). Withdrawal of the blade (2) may be achieved by rotating the handle (3) in the direction of the arrow shown in Figure 9. Inert gas contained within the envelope (4) flows into the cavity (26) to fill the cavity.

Referring now to Figure 10, the next step may be that the handle (3) is disconnected from the blade (2). The membrane forming the envelope (4) is stretched, as shown in Figure 10. Using a conventional heat-sealing device, the membrane of the envelope (4) is joined together and heat-sealed to form an air-tight seal (12). A second heat seal (12a) is formed in the membrane adjacent to the base pad (20) As shown in Figure 11, the membrane is now cut between the two heat seals (12, 12a) along a line (13). Thus, the sample has been taken without loss of the integrity of the environment encapsulating the product. The envelope (4) is divided into two separately sealed airtight portions; The portion (18) bonded to the product (10) by sealing means (5) and the portion (19) encapsulating the sampling blade (2) and the sample (11), and both containing inert gas. - 10 Finally, the heat seal (12a) of the portion (18) may be attached to the upper surface of the base pad (20) or to the exterior of the wrapping film (25). Thus, the sample (11) of the cheese block (10) has been removed without permitting the ambient air from entering the wrapping film (25) which seals the cheese block (10). Therefore the cheese block (10) remains uncontaminated.

A second embodiment of a sampling device of the invention is illustrated in Figure 12. This device is particularly suitable for extracting samples from products in a powder, or essentially granular form, such as dehydrated foodstuffs, sugars, flour and pharmaceuticals e.g. bulk pharmaceutical powders and the like.

Figure 12 shows a sampling device (51). The sampling device (51) comprises a hollow sampling tube (52), an envelope (54), a sealing means (5), a collar (56) having an aperture (57), a lid (58), and a sample receiving container (59).

The sampling tube (52) comprises a hard durable material preferably with one tapered end (53), the tapered end (53) having sharpened edges. The sampler (1) may be disposable with a reusable handle (3). It is desired that the sampler (1) is biodegradable.

The sampling tube (52) extends through the aperture (57). The aperture (57) is of sufficient diameter to hold the sampling tube (52) in place but the sampling tube (52) is displaceable along its longtitudinal axis through the aperture (57).

The envelope (54) comprises a durable flexible membrane. Suitably the envelope (54) is made from a transparent non-permeable polymeric film. The envelope (54) encapsulates the sampling tube (52).

Suitably the envelope (54) extends from the collar (56) in dimensions sufficient to allow ease of movement of the sampling tube (52) along its longitudinal axis.

The sealing means (5) is attached to the envelope (54) by an airtight bond. The sealing means (5) is similar in construction to - 11 that of the first embodiment described above. That is, it comprises a base pad (20) which is bonded, to the lower end of the envelope (54). The base pad (20) comprises an adhesive tape (21) having an adhesive layer (22) on the surface remote from the envelope (54). A removable protective covering film (23), which may be a polymeric film, protects the adhesive layer (22) when not in use. The peripheral edges of the adhesive tape (21) are protected by a rigid backing (24) of flexible polyethylene. The rigid backing (24) comprises an aperture (27). The aperture (27) is large enough to accommodate the sampling tube (52).

The envelope (54) is sealed in an airtight manner to the rigid backing (24) between the circumference of the aperture (27) and the edge of the rigid backing (24).

The sealing means (5) is attached to the envelope (54) by an airtight bond. The sealing means (5) defines a substantially flat surface. The sealing means (5) is attached to the exterior of the envelope (54) at the 'base end* of the envelope (54). The base end of the envelope (54) being that part furthest from the collar (56). Preferably the sealing means (5) is a one-sided adhesive tape. The back of the adhesive tape (21) is sealed to the base end of the envelope (54) by an airtight bond. The one-sided adhesive tape (21) has a protecting strip (23) on its adhesive side, and a backing of flexible polymeric film (24).The collar (56) preferably comprises a rigid plastic material in particular a plastic material suitable for heat sealing. The lid (58) is used to seal the aperture (57) when the sampling tube (52) has been removed. Preferably the lid (58) provides an airtight seal when placed over the aperture (57).

The receiving container (59) is attached to the collar (56) by an airtight bond. The receiving container (59) may comprise any suitable material and be in the form of a semi-rigid container, or a flexible bag. The receiving container (59) may be for example a plastics bag. Preferably the receiving container (59) is transparent. In particular the receiving container (59) is designed to have sufficient dimensions to hold the required amount of the sample.

Figures 14 to 16 illustrate one mode of operation of the second embodiment of the invention. The adhesive layer (22) of the base pad - 12 (20) is attached to the wall or wrapping (66) of the container of powder or granular products from which the sample is desired as described in the first embodiment of this invention. The sampling tube (52) is pushed through the adhesive tape (21), the wall or wrapping (66), and then into the product (60).

As illustrated in Figure 15, the free-flowing particles (61) of the product then flow through the sampling tube (52) into the receiving container (59).

As shown in Figure 16, the sampling tube (52) is then withdrawn from the aperture (57) and the flip-top lid (58) is placed as a cap on the aperture (57) thus sealing the aperture (57). The envelope (54) is then stretched as shown in Figure 16 and two heat seals (62) are made in the membrane of the envelope (54). The sampling tube (52) may be isolated by placing a heat seal each side of it. Inversion of the product and sampler may be required to stop the flow of the product into the sample container. Alternatively the sampling tube may be fitted with a lid to stem the flow of the product when so required. A cut (63) is then made between the two heat seals (62) and the envelope (54), is thus divided into two portions, one portion (64), attached to the product (60) and the other portion (65) encapsulating the sampling tube (52).

The heat-seal (62) of the portion (64) may be bonded, for example by heat-sealing or by adhesive, to the wall or wrapping (66) of the product (60).

In this way the sample has been removed from the product (60), and the wall or wrapping (66) of the product (60) has been re-sealed without permitting the entry of contaminated air into the product (60). Likewise, the sample is retained in the sealed container (59).

If desired, the envelope and container (59) may first be filled with an inert gas, or with sterilised air, as described with reference to the first embodiment. The gas displaced from the container (59) by entry of the sample (61) enters the wall or wrapping (66) of the product (60).

Claims (7)

1. 5 1. A sampling device for extracting a sample from a sealed bulk product (10, 60) comprising a sample extraction means (

2. ,52) insertable through the product seal (25, 66) into the bulk product (10, 60) for extraction of the sample (11,61) and a receiving means (19, 59) for receiving and containing the extracted sample (11, 61), characterised 10 in that the sample extraction means (2,52) is contained within a sealed air-tight encapsulating means (4, 54) and has sealing means (5) for connecting the encapsulating means (4, 54) to the seal (25, 66) of the bulk product (10, 60), whereby said sealing means (5) and encapsulating means (4, 54) may be used to reseal the bulk product after extraction 15 of the sample (11, 61).2. A sampling device as claimed in claim 1, characterised in that the encapsulating means comprises an air-tight envelope (4, 54) comprised of a flexible membrane within which the sample extraction means (2, 52) 20 is located, and means (12, 62) being provided for sealing the envelope (4, 54) after extraction of the sample (11, 61).

3. A sampling device as claimed in claim 1, characterised in that the receiving means for containing the extracted sample is a portion 25 (19,65) of the envelope (4, 54)

4. A sampling device as claimed in claim 1, characterised in that the receiving means for containing the extracted sample is a container (59) 30 5. A sampling device as claimed in claim 1 wherein the sample extraction means comprises a hollow cylindrical tube (52) or a concave part-circular shaped blade (2). 6. A sampling device according to claim 1 wherein the sealing means 35 (5) comprises a one-sided adhesive tape (21) preferably the non-adhesive side is sealed to the exterior of the envelope (4, 54) at that area of the envelope (4,54) which is directly below the extraction means (2, 52), and the one-sided adhesive tape (21) has a protecting cover (23) on the adhesive layer (22) of the tape. - 14 7. A sampling device according to any preceding claim wherein the environment within the envelope comprises an inert gas or a defined

5. Atmosphere.

6. 8. A sampling device according to any preceding claims wherein the sampling device is aseptically sterilised or manufactured in a sterile manner.

7. 9. An aseptic sampling device according to claim 7 wherein the sterilisation process comprises exposure to a sufficient dose of gamma radiation. 15 10. A method of aseptical ly removing a sample from a bulk product (10, 60) by means of a sampling device as claimed in any of the preceding claims, characterised in that the method comprises the steps of: (i) bonding the sealing means (5) of the encapsulating 20 means (4, 54) to provide an air-tight seal between the encapsulating membrane and the wrapping (25, 66) or container enclosing the bulk product (10, 60) (ii) piercing the sealing means (5) or a layer thereof with 25 the sampling means (2, 52) and inserting the sampling means (2, 52) through the product wrapping (23, 66) and into the bulk product (10, 60) (iii) removing a sample (11, 61) of the bulk product, and the 30 sampling means (2, 52) into the receiving means (19, 59), and (iv) re-sealing the wrapping (23, 66) of the bulk product by means of the sealing means (5) and the encapsulating means