JP6406400B2 - Adjustment method of content filling system - Google Patents

Description

  The present invention relates to a method for confirming initial germs in a content filling system.

  An aseptic filling system (aseptic filling system) is known in which a sterilized container (PET bottle) is filled with sterilized contents in an aseptic environment, and then the container is closed with a cap. Specifically, in the aseptic filling system, the molded container is supplied to the aseptic filling system, and the container is sprayed with an aqueous hydrogen peroxide solution as a sterilizing agent. This is then dried to sterilize the container and then aseptically filled into the container. As another method, a small amount of a sterilizing agent is dropped on the inner surface of the container at the time of molding the container, and the inner surface of the container is sterilized with vapor of a sterilizing agent (hydrogen peroxide) sealed and vaporized. There is also a method of supplying a container to an aseptic filling system, sterilizing the outer surface of the container in the aseptic filling system, and then aseptically filling the contents by opening the mouth.

  By the way, for example, before actually filling the container at the initial stage of the aseptic filling system, it is necessary to confirm whether or not the sterility of the system is ensured. For this reason, various tests for confirming the sterility of the system are performed. In order to comprehensively evaluate the sterility of the aseptic filling system at the final stage after performing such various tests, an evaluation method using a container filled with a culture medium is performed.

  For example, Patent Document 1 discloses a method for verifying the sterility level of a container by filling the container with a sterilized medium.

  However, in an aseptic filling system, it is conceivable that containers and caps are contaminated from the beginning. In such a case, even if the contents are aseptically filled into the container using an aseptic filling system, there is a possibility that the bacteria may propagate inside the finished beverage product. For example, measures such as increasing the amount of the disinfectant are taken. Necessary. Therefore, it is important to accurately know in advance how much the containers and caps are contaminated with bacteria and the initial number of bacteria in the containers and caps (the number of bacteria attached to the containers and caps before filling). is there.

JP 2010-36973 A

  The present invention has been made in consideration of such points, and in the content filling system, it is possible to accurately grasp initial germs adhering to a container or a cap using actual production equipment. The purpose is to provide a method for confirming bacteria.

  The present invention provides a container sterilization apparatus that sterilizes a container, a filling apparatus that fills the container with contents, and a content filling system that includes a cap mounting apparatus that closes the container with a cap. A method for confirming initial germs, wherein the container is sterilized by the container sterilizer, and the container is transported to the filling device without using the filling device. A step of filling a medium; a step of closing the container with the cap using the cap mounting device; and a step of verifying whether or not bacteria remain in the medium in the container. It is the first germ confirmation method characterized by the above.

  The present invention is the initial germ confirmation method characterized by further comprising a step of preparing sterilization conditions in the container sterilizer based on the result of the verification.

  The present invention uses a content filling system having a filling device for filling a container with a content, a cap sterilization device for sterilizing a cap, and a cap mounting device for closing the container with the cap. A method for confirming initial germs, the method for confirming initial germs, the step of filling the container with a medium using the filling device, and the cap sterilization without sterilizing the cap by the cap sterilizer. A step of transporting to a mounting device, a step of closing the container with the cap using the cap mounting device, and a step of verifying whether or not bacteria survive or propagate in the culture medium in the container. It is the first germ confirmation method characterized by having provided.

  The present invention is the first germ confirmation method, further comprising a step of preparing sterilization conditions in the cap sterilizer based on the result of the verification.

  The present invention is the first bacterial confirmation method, wherein the content is acidic and the pH of the medium is 3.5 or more and 4.6 or less.

  The present invention is the first bacterial confirmation method, wherein the content is neutral and the pH of the medium is 6 or more and 8 or less.

  According to the present invention, initial germs attached to a container or a cap can be grasped.

FIG. 1 is a schematic plan view showing a content filling system used in the first germ confirmation method according to an embodiment of the present invention. FIG. 2 is a flowchart showing a method for confirming initial germs according to an embodiment of the present invention. FIG. 3 is a schematic plan view showing a content filling system when the initial germ confirmation method according to one embodiment of the present invention is executed. FIG. 4 is a flowchart showing a first germ confirmation method according to a modification. FIG. 5 is a schematic cross-sectional view showing a sterilizer for a content filling system used in the method for confirming initial germs.

  Embodiments of the present invention will be described below with reference to the drawings. 1 to 3 are views showing an embodiment of the present invention.

(Content filling system)
First, a content filling system (aseptic filling system, aseptic filling system) according to the present embodiment will be described with reference to FIG.

  A content filling system 10 shown in FIG. 1 is a system that fills bottles (containers) 30 with contents such as beverages. The bottle 30 can be produced by biaxially stretch blow molding a preform produced by injection molding a synthetic resin material. As the material of the bottle 30, it is preferable to use a thermoplastic resin, particularly PE (polyethylene), PP (polypropylene), PET (polyethylene terephthalate), or PEN (polyethylene naphthalate). In addition, the container may be glass, can, paper, pouch, or a composite container thereof. In this embodiment, a case where a bottle is used as a container will be described as an example.

  As shown in FIG. 1, the content filling system 10 includes a bottle supply unit 21, a sterilizer 11, an air rinse device 14, a sterile water rinse device 15, a filling device (filler) 20, and a cap mounting device (capper). , Winding and plugging machine) 16 and a product bottle carrying-out part 22. From the upstream side to the downstream side along the conveying direction of the bottle supply unit 21, the sterilizer 11, the air rinse device 14, the sterile water rinse device 15, the filling device 20, the cap mounting device 16, and the product bottle carry-out unit 22. They are arranged in this order. In addition, a plurality of transport wheels 12 for transporting the bottle 30 between these devices are provided between the sterilizer 11, the air rinse device 14, the sterile water rinse device 15, the filling device 20, and the cap mounting device 16. Yes.

  The bottle supply unit 21 sequentially receives empty bottles 30 from the outside to the content filling system 10 and conveys the received bottles 30 toward the sterilizer 11.

  A bottle forming unit (not shown) for forming the bottle 30 by biaxially stretching blow-molding the preform may be provided on the upstream side of the bottle supply unit 21. As described above, the steps from supplying the preform to forming the bottle 30 to filling the bottle 30 with contents and closing the bottle 30 may be performed continuously. In this case, since it can be transported from the outside to the content filling system 10 not in the form of the bottle 30 with a large volume but in the form of a preform with a small volume, the transportation cost can be reduced.

  The sterilizer 11 sterilizes the inside of the bottle 30 by spraying a sterilizing agent onto the bottle 30. Thereby, the bottle 30 is sterilized by the bactericidal agent before filling the contents, and the bacterial spores are allowed to survive but the bacterial vegetative cells, mold and yeast are not allowed to survive. As the disinfectant, for example, a hydrogen peroxide aqueous solution is used. In the sterilizer 11, a mist or gas of an aqueous hydrogen peroxide solution is generated, and the mist or gas is sprayed on the inner and outer surfaces of the bottle 30. Since the inside of the bottle 30 is sterilized with the mist or gas of the hydrogen peroxide solution in this way, the inner surface of the bottle 30 is sterilized without unevenness.

  The air rinsing device 14 removes foreign substances, hydrogen peroxide, and the like from the bottle 30 while activating the hydrogen peroxide by supplying sterile heated air or room temperature air to the bottle 30.

  The aseptic water rinsing apparatus 15 performs washing with aseptic 15 ° C. to 85 ° C. water on the bottle 30 sterilized with hydrogen peroxide as a sterilizing agent. As a result, the hydrogen peroxide adhering to the bottle 30 is washed away, and foreign matters are removed.

  In the present embodiment, the container sterilization apparatus 13 is configured by the sterilization apparatus 11 described above.

  The filling device 20 fills the bottle 30 with the contents that have been sterilized in advance from the mouth of the bottle 30. In this filling device 20, the empty bottle 30 is filled with contents. In the filling device 20, the contents are filled into the bottle 30 while the plurality of bottles 30 are rotated (revolved). This content may be filled in the bottle 30 at room temperature. The contents are sterilized by heating or the like in advance, cooled to room temperature of 3 ° C. or higher and 40 ° C. or lower, and then filled into the bottle 30. As described above, the survival of bacterial spores is allowed in the bottle 30. For this reason, as before, the bottle 30 is filled with the contents heated to a high temperature, the bottle 30 is filled with the contents, and held for a long time, or the bottle 30 is filled and closed with the cap 33. It is not necessary to heat and sterilize the bottle 35 (described later) from the outside.

  By the way, the contents filled from the filling device 20 have predetermined characteristics that affect the propagation of bacteria. In the present embodiment, the predetermined characteristic may be the pH of the contents. More specifically, the content may consist of an acidic beverage. The acidity of this beverage is preferably less than pH 4.6, more preferably less than pH 4.0. Examples of beverages having a pH of 4.0 or more and pH 4.6 or less include tomato juice and vegetable juice, and beverages having a pH of less than 4.0 include, for example, lemon tea, orange juice, dairy carbonated beverages, functional beverages, carbonated beverages. There are lemon juice, grape juice, and juice juice.

  In general, bacterial spores remain bacteriostatic without germination in liquids that are somewhat acidic (eg, less than pH 4.6, preferably less than 4.0), so that the contents are spoiled. Saved without. Therefore, as described above, the bacterial spores remain alive in the bottle 30 before being filled with the filling device 20, but germination of the bacterial spores can be suppressed (for example, less than pH 4.6, preferably By filling the bottle 30 with sterilized contents having acidity (less than 4.0), the beverage is prevented from being altered or spoiled.

  The cap mounting device 16 closes the bottle 30 by mounting a cap 33 on the mouth of the bottle 30. In the cap mounting device 16, the mouth of the bottle 30 is closed by a cap 33 and sealed so that outside air and microorganisms do not enter the bottle 30. In the cap mounting device 16, a plurality of bottles 30 filled with the contents are rotated (revolved), and the cap 33 is mounted on the mouth thereof. In this manner, the product bottle 35 is obtained by attaching the cap 33 to the mouth portion of the bottle 30.

  The cap 33 is sterilized by the cap sterilizer 18 in advance. The cap sterilizer 18 is disposed, for example, inside the aseptic chamber 70 (described later) and in the vicinity of the cap mounting device 16. In the cap sterilization device 18, a large number of caps 33 carried in from the outside of the content filling system 10 are collected in advance and conveyed in a row toward the cap mounting device 16. On the way of the cap 33 toward the cap mounting device 16, hydrogen peroxide mist or gas is sprayed toward the inner and outer surfaces of the cap 33, and then dried with hot air and sterilized.

  The product bottle unloading unit 22 is configured to continuously unload the product bottle 35 on which the cap 33 is mounted by the cap mounting device 16 toward the outside of the content filling system 10.

  The content filling system 10 has a sterile chamber 70. The sterilization device 11, the air rinsing device 14, the sterilized water rinsing device 15, the filling device 20, the cap sterilization device 18, and the cap mounting device 16 described above are accommodated in the sterilization chamber 70. Such a content filling system 10 may comprise, for example, an aseptic filling system. In this case, the inside of the sterilization chamber 70 is maintained in a sterilized state.

  Alternatively, the content filling system 10 may be a high temperature filling system that fills the content at a high temperature of 85 ° C. or more and less than 100 ° C. Moreover, the intermediate temperature filling system which fills the content under intermediate temperature 55 degreeC or more and less than 85 degreeC may be sufficient. On the other hand, the technical idea according to the present embodiment can be applied to aseptic packaging using post-sterilization such as retort sterilization.

(Content filling method)
Next, a content filling method using the above-described content filling system 10 (FIG. 1) will be described. Hereinafter, a filling method in a normal state, that is, a content filling method for manufacturing a product bottle 35 by actually filling the bottle 30 with contents such as a beverage will be described.

  First, a plurality of empty bottles 30 are sequentially supplied from the outside of the content filling system 10 to the bottle supply unit 21. The bottle 30 is sent from the bottle supply unit 21 to the sterilizer 11 by the transport wheel 12 (container supply process).

  Next, in the sterilization apparatus 11 constituting the container sterilization apparatus 13, the bottle 30 is sterilized using an aqueous hydrogen peroxide solution that is a sterilizing agent (sterilization process). At this time, the hydrogen peroxide solution is a gas or mist that has been vaporized once above the boiling point, and is supplied toward the bottle 30. The mist of the hydrogen peroxide solution adheres to the entire inner surface of the bottle 30 and sterilizes the vegetative cells, molds and yeast of the bacteria in the bottle 30. The amount of hydrogen peroxide mist supplied into the bottle 30 is, for example, not less than 5 μL / bottle and not more than 50 μL / bottle, and in the case of hydrogen peroxide gas, not less than 1 mg / L and not more than 5 mg / L. The force kills vegetative cells, molds and yeasts of bacteria, but does not kill bacterial spores. Thereby, the usage-amount of hydrogen peroxide can be reduced.

  Subsequently, the bottle 30 is sent to the air rinsing device 14 by the transport wheel 12, and in the air rinsing device 14, by supplying aseptic heated air or room temperature air, the hydrogen peroxide is activated and the foreign matter is discharged from the bottle 30. Hydrogen peroxide and the like are removed. Next, the bottle 30 is conveyed to the sterile water rinsing device 15 by the conveyance wheel 12. In this aseptic water rinsing apparatus 15, washing with aseptic 15 ° C. to 85 ° C. water is performed (rinsing step). Specifically, sterile 15 ° C. to 85 ° C. water is supplied into the bottle 30 at a flow rate of 5 L / min to 15 L / min. At that time, the bottle 30 is preferably turned upside down, and aseptic water is supplied into the bottle 30 from the mouth portion facing downward, and the aseptic water flows out of the bottle 30 from the mouth portion. With this warm water, the hydrogen peroxide adhering to the bottle 30 is washed away, and foreign matters are removed.

  Subsequently, the bottle 30 is transported to the filling device 20 by the transport wheel 12. In the filling device 20, while the bottle 30 is rotated (revolved), the contents are filled into the bottle 30 from the mouth (filling step).

  Before the bottle 30 is filled with the filling device 20, the contents are prepared in advance and a heat sterilization process is performed. As described above, the contents may have a predetermined pH that is a characteristic that affects the propagation of bacteria. Specifically, the contents may consist of an acidic beverage, preferably less than pH 4.6, more preferably less than pH 4. The heating temperature is generally about 60 ° C. or higher and 120 ° C. or lower when the acidity of the content is less than pH 4.0, and about 115 ° C. or higher and 150 ° C. or lower when the pH is 4.0 or higher. Thereby, all the microorganisms that can grow in the product bottle 35 in the contents before filling are sterilized. The heat-sterilized contents are cooled to a room temperature of about 3 ° C. to 40 ° C.

In the filling device 20, the sterilized bottle 30 is filled with the sterilized contents cooled to room temperature at room temperature. The temperature of the contents at the time of filling is, for example, about 3 ° C. or more and 40 ° C. or less. As described above, the acidity of the content is preferably less than pH 4.6, more preferably less than pH 4, and specifically, tomato juice, vegetable juice, lemon tea, orange juice, milky carbonated drink, function Drinks, carbonated lemon juice, grape juice, fruit juice juice and the like. That is, according to such a content filling method, it is possible to manufacture a product bottle 35 filled with almost all kinds of beverages except barley tea having a pH of 4.6 or more, mixed tea and beverages containing milk. Needless to say, a product bottle 35 of a carbonated beverage that does not contain animal or plant composition components such as cola and cider and has a carbon dioxide pressure of 1.0 kg / cm ² (20 ° C.) or more can also be produced.

  Subsequently, the bottle 30 filled with the contents is transported to the cap mounting device 16 by the transport wheel 12.

  On the other hand, the cap 33 is previously sterilized by the cap sterilizer 18 (cap sterilization step). During this time, the cap 33 is first carried into the cap sterilizer 18 from the outside of the content filling system 10. Subsequently, the cap 33 is sprayed with hydrogen peroxide mist or gas in the cap sterilization device 18, and the inner and outer surfaces thereof are sterilized, dried with hot air, and sent to the cap mounting device 16.

  Next, in the cap mounting device 16, a product bottle 35 is obtained by mounting a sterilized cap 33 on the mouth of the bottle 30 conveyed from the filling device 20 (cap mounting step).

  Thereafter, the product bottle 35 is conveyed from the cap mounting device 16 to the product bottle carry-out unit 22 and carried out to the outside of the content filling system 10.

  Each process from the sterilization process to the cap mounting process is performed in an aseptic atmosphere surrounded by an aseptic chamber 70, that is, in an aseptic environment. The sterilization chamber 70 is sterilized in advance by spraying with hydrogen peroxide, discharging warm water, etc. so as to allow the survival of bacterial spores but not the survival of bacterial vegetative cells, fungi and yeast. Then, positive sterilized air is supplied into the sterilization chamber 70 so that the sterilization air always blows out of the sterilization chamber 70 after the sterilization process.

  In addition, it is preferable that the production (conveyance) speed of the bottle 30 in the content filling system 10 is 100 bpm or more and 1500 bpm or less. Here, bpm (bottle per minute) refers to the conveyance speed of the bottle 30 per minute.

(First bacteria confirmation method in content filling system)
Next, the first germ confirmation method for verifying the sterility of the bottle 30 using the above-described content filling system 10 (FIG. 1) will be described.

  The initial germ confirmation method according to the present embodiment confirms whether or not the sterility of the bottle 30 filled with the contents in the content filling system 10 is ensured. This initial germ confirmation method is, for example, an initial stage immediately after the content filling system 10 is completed, that is, before actually filling the bottle 30 using the content filling system 10 and starting production of the product bottle 35. May be done. Alternatively, the method for confirming initial germs according to the present embodiment affects sterility when, for example, any change occurs in the process or apparatus in the content filling system 10 or when the content filling system 10 is not used for a certain period of time. It may be performed when there is a risk of affecting. Alternatively, this initial germ confirmation method may be performed periodically every predetermined filling cycle regardless of whether or not there is a risk of affecting sterility.

  First, before performing the initial germ confirmation method according to the present embodiment, each element of the content filling system 10 is individually tested to determine whether sterility is ensured. Specifically, for example, a test whether the content supply line is heated correctly (SIP temperature increase confirmation test), a test whether the bottle 30 and the cap 33 are correctly sterilized (bottle sterilization test) , A cap sterilization test) and a test (chamber sterilization test) as to whether or not the aseptic chamber 70 is sterilized.

  After performing such a test, in order to evaluate the sterility of the bottle 30, the first germ confirmation method according to the present embodiment is executed. Specifically, a large number of bottles 30 are allowed to flow through the content filling system 10 and the bottles 30 are not sterilized by the container sterilization apparatus 13 (sterilization apparatus 11), but instead of the contents actually filled in each bottle 30. Then, a predetermined medium is filled and the cap 33 is closed. Thereafter, it is confirmed that the medium filled in each bottle 30 does not rot after a lapse of a certain period of time (a method for confirming initial germs in a container).

  Hereinafter, the initial germ confirmation method (the initial germ confirmation method of the container) of the content filling system 10 according to the present embodiment will be further described with reference to FIGS. 2 and 3. FIG. 2 is a flowchart showing the initial germ confirmation method according to the present embodiment, and FIG. 3 is a schematic plan view showing the content filling system when executing the initial germ confirmation method according to the present embodiment. In FIG. 3, the same parts as those in the content filling system 10 shown in FIG.

First, as shown in FIG. 3, an empty bottle 30 for verification is passed through the content filling system 10.
In this case, an empty bottle 30 is supplied from the outside to the bottle supply unit 21 of the content filling system 10 (container supply process, step S1 in FIG. 2). The number of bottles 30 is determined in advance, and may be a predetermined number of, for example, 100 or more and 300,000 or less (preferably 1,000 or more and 30,000 or less).

  Next, the bottle 30 is sent to the sterilizer 11 of the container sterilizer 13. The sterilizer 11, the air rinse device 14, and the sterile water rinse device 15 of the container sterilizer 13 are stopped in advance, and the bottle 30 is not sterilized. For this reason, without sterilizing the bottle 30 by the sterilizer 11, the bottle 30 passes through the sterilizer 11, the air rinse device 14, and the sterile rinse device 15 as it is and is conveyed to the filling device 20 (non-sterilized container conveying step, Step S2 in FIG. The bottle 30 may be sent to the filling device 20 using another detour route instead of passing through the sterilizing device 11, the air rinsing device 14, and the aseptic rinsing device 15.

  Here, a method of conveying the inside of the aseptic chamber 70 without sterilizing only the bottle 30 and filling the medium with the filling device (filler) 20 as will be described later will be described. First, in the case of the hydrogen peroxide gas method, the sterilizer 11 bypasses the hydrogen peroxide gas so as not to be introduced into the bottle 30 or stops the supply of the hydrogen peroxide gas. In addition, when air is supplied into the bottle 30, the number of initial germs in the bottle 30 cannot be measured accurately, and thus it is necessary to bypass the air.

  FIG. 5 is a schematic cross-sectional view showing the sterilizer 11. As shown in FIG. 5, a wheel 51 that is rotated by power from a predetermined drive source is horizontally attached to a turning shaft 53 that stands on a machine base 52. A column 54 extends upward from the surface of the wheel 51, and a manifold 55 into which hydrogen peroxide gas flows is fixed to the upper end of the column 54. From the upper center of the manifold 55, a conduit 56 extends upward on an extension line of the axis of the pivot 53, and this conduit 56 is held by a frame member of a sterilization chamber 70 connected to the machine base 52 via a bearing 57. . Thereby, the manifold 55 can rotate around the turning shaft 53 integrally with the wheel 51.

  Further, another support column 58 extends upward from the surface of the wheel 51, and the gripper 60 of the bottle 30 is attached to the upper portion of the support column 58. A number of pillars 58 and grippers 60 are arranged around the wheel 51 at a predetermined pitch. A number of grippers 60 are connected to the wheel 51 via the support column 58 and rotate with the rotation of the wheel 51.

  From around the manifold 55, hydrogen peroxide gas supply pipes 59 extend toward the grippers 60, and nozzles 61 are attached to the tips of the supply pipes 59. The nozzle 61 is fixed to the column 58, and the opening at the tip of the nozzle 61 faces the mouth of the bottle 30 held by the gripper 60. Thereby, when the wheel 51 rotates, the nozzle 61 turns around the turning shaft 53 together with the bottle 30 held by the gripper 60, and sprays hydrogen peroxide gas onto the bottle 30. A tunnel 62 is provided around the wheel 51 so as to surround the path of the bottle 30 held by the gripper 60.

  A conduit 63 is connected to the upper end of the conduit 56 of the manifold 55 via a seal member 64. The conduit 56 is rotated integrally with the manifold 55 with respect to the conduit 63, and the seal member 64 prevents leakage of hydrogen peroxide gas from the connection portion of both the tubes 56 and 63. A first valve 41 that controls passage of hydrogen peroxide gas in the conduit 63 is attached to the conduit 63. A bypass conduit 67 branches from the upstream side of the first valve 41. The bypass conduit 67 communicates with the inside of the sterilization chamber 70. A second valve 43 that controls the passage of hydrogen peroxide gas in the bypass conduit 67 is attached to the bypass conduit 67. The bypass conduit 67 may extend from between the bearing 57 and the nozzle 61.

  A gas supply device including a blower 65, a HEPA (High Efficiency Particulate Air Filter) filter 66, and an electric heater 69 is provided on the upstream side of the conduit 63. The hydrogen peroxide addition device 68 is incorporated in one or both of the front and rear of the electric heater 69. In the case where the hydrogen peroxide addition device 68 is installed on the downstream side of the electric heater 69, it is preferable that the piping is mixed with hydrogen peroxide gas. If hydrogen peroxide is not in a gas state, the residual value of hydrogen peroxide tends to increase. On the other hand, when the hydrogen peroxide addition device 68 is installed upstream of the electric heater 69, the hydrogen peroxide may be added into the pipe in a liquid form such as a spray. In this case, the set temperature of the electric heater 69 is preferably not less than the boiling point of the sterilizing agent to be supplied, but may be 100 ° C. or more (preferably 130 ° C. or more) according to the sterilization strength of the bottle 30. Further, another electric heater may be provided on the further upstream side of the spray, and sprayed into aseptic hot air (80 ° C. or higher). Alternatively, the hydrogen peroxide addition device 68 may be incorporated both before and after the electric heater 69. When the material of the bottle 30 is PET (polyethylene terephthalate), hydrogen peroxide is easily adsorbed and the residual value is likely to increase. However, when the material is HDPE (high density polyethylene), the amount of hydrogen peroxide adsorbed is 1/5. 1/20, very few. Therefore, not only a method in which hydrogen peroxide water is gasified and added to aseptic air, but also a method in which hydrogen peroxide water is sprayed and mixed is adopted. The hydrogen peroxide gas blows out from the nozzle 61 to the bottle 30 through each supply pipe 59 and sterilizes the bottle 30. A pressure gauge 71 for measuring the pressure in the sterile chamber 70 is attached to the sterile chamber 70. Moreover, the disinfectant should just contain the density | concentration of 1% or more of hydrogen peroxide. A 35% hydrogen peroxide solution diluted with ethanol may be used.

  In FIG. 5, at the time of normal production, the first valve 41 of the sterilizer 11 is opened and the second valve 43 is closed, so that the hydrogen peroxide gas passes through the normally used conduit 63 to the bottle 30. Introduced in. On the other hand, when the first germ confirmation of the container is performed, the first valve 41 is closed and the bypass-side second valve 43 is opened. As a result, the hydrogen peroxide gas passes through the bypass conduit 67 and is not introduced into the bottle 30. In addition, when performing the first germ confirmation of the container, the first valve 41 may be opened and the second valve 43 on the bypass side may be opened.

  Similarly, in the next air rinsing process by the air rinsing apparatus 14, it is necessary to bypass the sterilized air or stop the supply of the sterilized air so that the inside of the bottle 30 is not replaced with the sterilized air. However, it is preferable to supply aseptic air into the aseptic chamber 70 in the same way as during normal production so that germs are not mixed into the aseptic chamber 70 in a positive pressure state. In addition, the structure of the air rinse apparatus 14 is good also as a structure substantially the same as the sterilizer 11 shown in FIG.

  In the case of equipment equipped with the sterile water rinsing device 15 as in the present embodiment, if the bottle 30 is washed with sterile water, the exact number of initial bacteria cannot be grasped. It is necessary to reduce the flow rate. If the machine is dry-operated with the sterile water rinse being stopped, the distributor of the sterile water rinse device 15 may be worn out and damaged. Therefore, it is preferable to minimize the flow rate while supplying sterile water. The same idea may be used in the case of a drug rinsing method using a peracetic acid preparation.

  Next, in the filling device 20, a predetermined amount of medium is filled into the bottle 30 from the mouth of the bottle 30 (medium filling step, step S3 in FIG. 2).

  Before filling the bottle 30 with the filling device 20, a culture medium is prepared in advance and a heat sterilization process is performed. The characteristics of the culture medium are the characteristics of the contents filled in the contents filling system 10 and are matched with the characteristics that affect the growth of bacteria. In the present embodiment, the pH of the medium is adjusted to be acidic in accordance with the pH of the contents. For example, the pH is 4.0 or more and 4.6 or less. More specifically, when the pH of the content is less than pH 4.0, the pH of the medium is preferably adjusted to pH 4.0, which is the upper limit thereof. Moreover, when the pH of the content is not less than pH 4 and less than 4.6, it is preferable that the pH of the medium is adjusted to pH 4.6 which is the upper limit. On the other hand, when the standard of the product having the highest pH among the product bottles 35 to be manufactured is, for example, pH 3.5 ± 0.2, the pH of the medium is set to pH 3.5, or the upper limit value of pH 3.7, or The sterility verification test may be performed by adjusting the pH to 3.8 or pH 3.9, which is slightly higher than the upper limit.

  Thus, by adjusting the culture medium to the characteristics of the contents and setting its pH to 3.5 or more and 4.6 or less, preferably 4.0 or more and 4.6 or less, the culture medium can survive bacterial spores. Is acceptable, but does not allow the survival of bacterial vegetative cells, mold and yeast. For this reason, the growth environment of the bacteria in the culture medium can be brought close to the contents actually filled.

  As such a medium, generally, as a carbon source, monosaccharides such as glucose and dextrose as organic carbon sources, disaccharides, polysaccharides, and sodium carbonate and sodium hydrogen carbonate as inorganic carbon sources are 0.2 to 3% by weight and 0.5 to 0.5% of casein peptone, chicken peptone, heart muscle peptone, gelatin peptone, soybean peptone, polypeptone, yeast extract, meat extract, ammonium sulfate, magnesium sulfate, nitrate, etc. as nitrogen source (including coenzyme) Prepared by dissolving 0.05% to 1% by weight of 3% by weight and sodium chloride, monopotassium phosphate, potassium monohydrogen phosphate, potassium dihydrogen phosphate, etc. as trace minerals or buffers. To do. The pH of the medium is adjusted by dissolving hydrochloric acid, tartaric acid, citric acid, sodium hydroxide, potassium hydroxide, etc. in the medium.

  The medium is sterilized by heating (UHT) or filter sterilization by a predetermined sterilization method in the liquid processing equipment 23 and is filled by the filling device 20. When a carbonated beverage is also produced by the liquid treatment equipment 23, it is necessary to install a carbon dioxide dissolving device (carbonator) 24 for adding carbon dioxide sterilized by filtration to the product liquid in front of the filling device 20. When the medium is filled, if carbon dioxide is added, the medium may have a bacteriostatic action. Therefore, the supply of carbon dioxide may be stopped or the carbon dioxide may be replaced with air. By changing the carbon dioxide gas to air, it becomes possible to check the sterility including the filtration filter of the carbon dioxide sterilization equipment (not shown).

  Subsequently, the bottle 30 filled with the culture medium passes from the filling device 20 under the gas replacement device 25 that replaces the gas in the head space in the bottle 30 and is sent to the cap mounting device 16. The gas replacement device 25 blows an inert gas (nitrogen or carbon dioxide) sterilized by filtration at the mouth of the bottle 30 during normal production, but when the medium is filled, the inert gas (nitrogen or carbon dioxide) is filled. ) Or stop the inert gas with air. By changing to air, it becomes possible to confirm sterility including the filtration filter of the gas displacement device 25 in the head space.

  On the other hand, the cap 33 is previously sterilized by the cap sterilizer 18 (cap sterilization step, step S8 in FIG. 2). The cap 33 is carried into the cap sterilization apparatus 18 from the outside of the content filling system 10 and sprayed with hydrogen peroxide mist or gas to sterilize the inner and outer surfaces, while activating hydrogen peroxide with hot air. It is removed, washed with sterile water and sent to the cap mounting device 16. This cap sterilization step is performed in the same manner as the cap sterilization step in the above-described normal content filling method.

  Subsequently, in the cap mounting device 16, the sterilized cap 33 sterilized by the cap sterilization device 18 is mounted on the mouth of the bottle 30 (cap mounting process, step S4 in FIG. 2). In addition, this cap mounting process is performed similarly to the cap mounting process in the normal content filling method mentioned above. In this way, the inside of the bottle 30 is filled with the culture medium, and the mouth portion is sealed with the cap 33, whereby the verification bottle 36 is obtained.

  Next, the verification bottle 36 filled with the culture medium is unloaded from the product bottle unloading unit 22 and boxed in the packaging process. The boxed case is tilted (or inverted) manually or automatically on the conveyor, and the medium is reliably brought into contact with the inner surface of the bottle 30 (medium contact process, step S5 in FIG. 4). Thereafter, the plurality of verification bottles 36 are transported to a constant temperature chamber 37 maintained at a predetermined temperature of 25 ° C. or higher and 40 ° C. or lower, and are left to stand and cultured in the constant temperature chamber 37 (culturing step, step of FIG. 2). S6). When the product bottle 35 is warmed and sold by a hot bender or the like, it is desirable to check the sterility of the thermophilic bacteria, and the verification bottle 36 is cultured at a temperature of 40 ° C. or higher and 65 ° C. or lower.

  After a predetermined period (for example, 3 days or more and 10 days or less), all the verification bottles 36 are taken out from the thermostatic chamber 37, and it is verified whether or not the bacteria survive or propagate in the culture medium in the verification bottle 36. (Verification process, step S7 in FIG. 2). As a result of this verification, if the number of verification bottles 36 in which the bacteria survive or have propagated is equal to or less than a predetermined number (for example, zero), it is determined that no initial bacteria have occurred in the bottle 30 and sterility is ensured. On the other hand, as a result of the verification, if the number of verification bottles 36 in which the bacteria survive or have propagated is equal to or greater than a predetermined number (for example, one or more), it is determined that the first germ has occurred in the bottle 30 and measures are taken. For example, the sterilization of the bottle 30 and the carry-in route may be performed, or the sterilization conditions in the container sterilization apparatus 13 (sterilization apparatus 11) may be prepared (strengthened). In some cases, the bottle 30 can be sufficiently sterilized by operating the container sterilizer 13 (sterilizer 11) depending on the type of bacteria. In this case, the bottle 30 is actually filled with contents such as a beverage. At this time, it can be determined that it is sufficient to operate the container sterilizer 13.

  As described above, according to the present embodiment, after the medium is filled in the bottle 30 that is not sterilized by the container sterilizer 13 and the cap 33 is closed, the bacteria survive or propagate in the medium in the bottle 30. Verify whether or not. Thereby, it is possible to accurately grasp the bioburden as to whether or not the first germ has occurred in the bottle 30 and to take a sterilization measure against the bottle 30 before actually filling the bottle 30 with contents such as beverages. Can do.

Further, according to the present embodiment, since the pH of the medium used in the verification is set to 4.0 or more and 4.6 or less in accordance with the acidic contents to be actually filled, Spores are allowed to survive, but bacterial vegetative cells, molds and yeasts are not allowed to survive.
Thereby, when comprehensively evaluating the sterility of the content filling system 10 using a culture medium, it is possible to verify the growth environment of the bacteria close to the actual content. Thereby, it is not necessary to make the equipment for sterilization excessive, the chemical | medical agent and heat energy which are required for sterilization can be reduced, and the manufacturing cost of the product bottle 35 can be reduced. For example, reducing the temperature of steam or hot water used for SIP (Sterilizing in Place) processing in the beverage supply system piping of the content filling system 10 or reducing the time for flowing steam or hot water. Can do.
In addition, the time required for performing the COP (Cleaning out of Place) process or the SOP (Sterilizing out of Place) process on the inside of the aseptic chamber 70 can be shortened.

  In addition, when the content to be actually filled is a low acidity or neutral beverage, the pH of the medium is 7.0 (6.0 to 8.0) as low as the general medium. It may be neutral. In this case, almost all bacteria can be detected.

  In the above description, the case of using a sterilization apparatus that performs hydrogen peroxide sterilization and hot water sterilization as the container sterilization apparatus has been described. After sterilizing bottle inner and outer surfaces with peracetic acid rinse, peracetic acid sterilization method to rinse inner and outer surfaces with sterile water or electron beam irradiating from the inner or outer surface of bottle to sterilize bottle and then electron rinsing with sterile air All sterilization devices such as sterilization method and UV sterilization can be applied. It may be used not only for sterilizing bottles but also for sterilizing preforms, cups and pouches. In the above description, a case where a PET bottle is used as a container is described as an example, and a medium for aerobic bacteria is used as a medium. However, the present invention is not limited to this. When a retort container such as canned food is used, a medium for anaerobic bacteria may be used as the medium.

(Modification)
Next, a modification of the present embodiment will be described.

  In embodiment mentioned above, the case where it verified whether the first germ was produced in the bottle 30 was demonstrated as an example. However, the present invention is not limited to this, and it may be verified whether or not the initial germ has occurred in the cap 33. That is, after a large number of bottles 30 are poured into the content filling system 10 and each bottle 30 is sterilized, each bottle 30 is filled with a predetermined medium instead of the contents actually filled. Next, the bottle 30 is closed with the cap 33 that is not sterilized by the cap sterilizer 18. Thereafter, it is confirmed that the medium filled in each bottle 30 does not rot after a certain period of time (a method for confirming the initial bacteria on the cap).

  Hereinafter, an initial germ confirmation method (cap initial germ confirmation method) of the content filling system 10 according to the present modification will be described with reference to FIGS. 3 and 4. FIG. 4 is a flowchart showing a first germ confirmation method according to a modification.

First, in the same manner as described above, an empty bottle 30 for verification is caused to flow through the content filling system 10.
In this case, an empty bottle 30 is supplied from the outside to the bottle supply unit 21 of the content filling system 10 (container supply process, step S11 in FIG. 4). The number of bottles 30 is determined in advance, and may be a predetermined number of, for example, 1,000 or more and 300,000 or less (preferably 3,000 or more and 30,000 or less).

  Next, the bottle 30 is sent to the sterilization apparatus 11 of the container sterilization apparatus 13, and the sterilization apparatus 11 performs a sterilization process on the bottle 30 using an aqueous hydrogen peroxide solution as a sterilizing agent (sterilization process, Step S12 in FIG. In addition, this sterilization process is performed similarly to the sterilization process in the normal content filling method mentioned above.

  Subsequently, the bottle 30 is sequentially sent to the air rinse device 14 and the sterile water rinse device 15, and the bottle 30 is cleaned with air and sterile water in the air rinse device 14 and the sterile water rinse device 15 (rinse). Step, step S13 in FIG. In addition, this rinse process is the same as the rinse process in the normal content filling method mentioned above.

  Next, the bottle 30 is conveyed to the filling device 20. In this filling device 20, a predetermined amount of the sterilized medium is filled into the bottle 30 from the mouth of the bottle 30 (medium filling step, step S14 in FIG. 4). In addition, this culture medium filling process is the same as the culture medium filling process in the initial germ confirmation method of the container mentioned above.

  On the other hand, the cap sterilizer 18 is stopped in advance, and the cap 33 is not sterilized. For this reason, the cap 33 passes through the cap sterilization device 18 as it is without being sterilized by the cap sterilization device 18 and is conveyed to the cap mounting device 16 (non-sterilization cap conveyance process, step S18 in FIG. 4). Note that the cap 33 may be sent to the cap mounting device 16 using another detour path instead of passing through the cap sterilization device 18.

  Subsequently, the bottle 30 filled with the culture medium is sent to the cap mounting device 16. In this cap mounting device 16, a cap 33 that has not been sterilized is mounted on the mouth of the bottle 30 (cap mounting step, step S15 in FIG. 4). In this way, the inside of the bottle 30 is filled with the culture medium, and the mouth is sealed with the non-sterile cap 33, whereby the verification bottle 36 is obtained.

  Next, the verification bottle 36 filled with the culture medium is unloaded from the product bottle unloading unit 22 and boxed in the packaging process. The case packed in a box is tilted (or inverted) manually or automatically on the conveyor, and the medium is reliably brought into contact with the inner surface of the cap 33 (medium contact process, step S16 in FIG. 4). Thereafter, the plurality of verification bottles 36 are transported to a constant temperature chamber 37 where they are left standing and cultured (culture process, step S17 in FIG. 4). This culturing step is the same as the culturing step in the above-described method for confirming the initial bacteria of a container.

  After a predetermined period (for example, 3 days or more and 10 days or less), all the verification bottles 36 are taken out from the thermostatic chamber 37, and it is verified whether or not the bacteria survive or propagate in the culture medium in the verification bottle 36. (Verification process, step S18 of FIG. 4). As a result of this verification, the bioburden of the actual cap can be accurately grasped. On the other hand, as a result of the verification, if the number of verification bottles 36 in which the bacteria survive or have propagated is equal to or greater than a predetermined number (for example, one or more), it is determined that initial germs have occurred in the cap 33 and measures are taken. For example, the cap 33 may be sterilized and the sterilization conditions in the cap sterilizer 18 may be prepared (strengthened). In addition, depending on the type of bacteria, the cap 33 may be sufficiently sterilized by operating the cap sterilizer 18. In this case, when the bottle 30 is actually filled with contents such as a beverage, the cap sterilizer 18 is used. It can be determined that it is sufficient to operate.

  As described above, according to the present modification, the sterilized bottle 30 is filled with the medium, and the cap 33 that is not sterilized by the cap sterilizer 18 is closed, and then the bacteria survive or propagate in the medium in the bottle 30. Verify whether or not. Thereby, it can be grasped | ascertained correctly whether the initial germs have arisen in the cap 33, and before filling the bottle 30 with content, such as a drink, the sterilization countermeasure with respect to the cap 33 can be taken.

  In addition, it may be verified at a time whether or not the first germ has occurred in either the bottle 30 or the cap 33 by combining the above-described embodiment and modification. That is, the bottle 30 is conveyed to the filling device 20 without sterilizing the bottle 30 by the container sterilization device 13, and the sterilized medium is filled into the unsterilized bottle 30 using the filling device 20. Subsequently, the cap 33 is conveyed to the cap mounting device 16 without sterilizing the cap 33 by the cap sterilizing device 18, and the bottle 30 is closed with the cap 33 that has not been sterilized using the cap mounting device 16. Thereafter, it may be verified whether or not the bacteria survive or propagate in the medium in the bottle 30.

  Next, specific examples in the above embodiment will be described.

Example 1
A beverage filling system of 600 bpm (bottle per minute) was used in which a sterilized beverage was filled at room temperature into a 500 mL capacity PET bottle sterilized in an aseptic atmosphere and sealed with a sterilized cap. Using this beverage filling system, 3000 PET bottles that were not sterilized were filled with a sterilized acidic medium having a pH of 4.0 at room temperature and closed with a sterilized cap. Next, these were cultured at 27 ° C. for 1 week, and then all PET bottles were inspected. As a result, there was only one PET bottle in which the medium was spoiled. When the bacteria contained in this spoiled medium were identified, they were bacteria with low drug resistance (Cladosporium cladosporioides). For this reason, when actually filling a PET bottle with a beverage, it was judged that it could be sufficiently sterilized by operating the container sterilizer.

(Example 2)
A beverage filling system of 600 bpm (bottle per minute) was used in which a sterilized beverage was filled at room temperature into a 500 mL capacity PET bottle sterilized in an aseptic atmosphere and sealed with a sterilized cap. Using this beverage filling system, 3000 sterilized PET bottles were filled with a sterilized acidic medium having a pH of 4.0 at room temperature and closed with a cap that was not sterilized. Next, these were cultured at 27 ° C. for 1 week, and then all PET bottles were inspected. As a result, there was only one PET bottle in which the medium was spoiled. When the bacteria contained in this spoiled medium were identified, it was estimated to be A. niger. For this reason, when actually filling the PET bottle with the beverage, it was determined that the cap sterilization apparatus could be sufficiently sterilized by operating.

DESCRIPTION OF SYMBOLS 10 Contents filling system 11 Sterilization apparatus 12 Conveyance wheel 13 Container sterilization apparatus 14 Air rinse apparatus 15 Aseptic rinse apparatus 16 Cap mounting apparatus 18 Cap sterilization apparatus 20 Filling apparatus 21 Bottle supply part 22 Product bottle carrying-out part 30 Bottle 33 Cap 35 Product bottle 36 Verification bottle 37 Constant temperature chamber 70 Aseptic chamber

Claims (4)

A method for adjusting a content filling system comprising: a container sterilization device for sterilizing a container; a filling device for filling the container with contents; and a cap mounting device for closing the container with a cap;
Conveying the container to the filling device;
Filling the medium with the medium using the filling device;
Capping the container with the cap using the cap mounting device;
A step of verifying whether or not the bacteria survive or propagate in the medium in the container,
Based on the result of the verification, the temperature of the steam or hot water used when sterilizing the inside of the beverage supply system piping of the content filling system is lowered , or the time for flowing the steam or hot water is shortened. A method for adjusting a content filling system.   The method for adjusting a content filling system according to claim 1, further comprising a step of preparing sterilization conditions in the container sterilizer based on the result of the verification.   The method for adjusting a content filling system according to claim 1 or 2, wherein the content is acidic, and the pH of the medium is set to 3.5 or more and 4.6 or less.   The method for adjusting a content filling system according to claim 1 or 2, wherein the content is neutral and the pH of the medium is 6 or more and 8 or less.

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