JP7150667B2 - Method for confirming initial bacteria in content filling system - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for confirming initial bacteria 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 capped with a cap. Specifically, in an aseptic filling system, molded containers are fed into the aseptic filling system, and within the aseptic filling system, the containers are sprayed with an aqueous hydrogen peroxide solution as a sterilant. It is then dried to sterilize the container, which is then aseptically filled with the contents. As another method, a small amount of sterilizing agent is dripped on the inner surface of the container when the container is molded, the mouth is sealed, and the vapor of the vaporized sterilizing agent (hydrogen peroxide) is used to sterilize the inner surface of the container. There is also a method of supplying the container to an aseptic filling system, sterilizing the outer surface of the container in the aseptic filling system, and then opening the mouth and aseptically filling the contents.

By the way, for example, in the initial stage of an aseptic filling system, before actually starting to fill containers, it is necessary to confirm whether or not the sterility of the system is ensured. For this reason, various tests are performed to confirm the sterility of the system. After conducting these various tests, in order to comprehensively evaluate the sterility of the aseptic filling system in the final stage, an evaluation method using a container filled with culture medium is performed.

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

However, in an aseptic filling system, it is possible that the container or cap may be contaminated from the beginning. In such cases, even if the content is aseptically filled into the container using an aseptic filling system, bacteria may grow inside the finished beverage product. necessary. Therefore, it is important to know in advance to what extent the container or cap is contaminated with bacteria, and to accurately determine the number of initial bacteria on the container or cap (the number of bacteria adhering to the container or cap before filling). be.

JP 2010-36973 A

The present invention has been made in consideration of such points. An object of the present invention is to provide a bacterium confirmation method.

The present invention uses a content filling system having a container sterilizing device for sterilizing a container, a filling device for filling the content into the container, and a cap attaching device for closing the container with a cap. A first germ confirmation method for confirming the first germs, comprising a step of conveying the container to the filling device without sterilizing the container by the container sterilization device; a step of filling a medium; a step of closing the container with the cap using the cap fitting device; and a step of verifying whether or not bacteria survive or propagate in the medium in the container. It is a method for confirming the first onset of bacteria characterized by

According to the present invention, there is provided a method for confirming the first bacteria, further comprising a step of adjusting sterilization conditions in the container sterilization apparatus based on the result of the verification.

The present invention uses a content filling system having a filling device that fills a container with content, a cap sterilization device that sterilizes a cap, and a cap mounting device that closes the container with the cap. A first germ confirmation method for confirming the first germs, comprising the steps of filling a culture medium into the container using the filling device, and removing the cap without sterilizing the cap with the cap sterilization device a step of conveying to a mounting device; a step of closing the container with the cap using the cap mounting device; It is a method for confirming the first onset of bacteria, characterized by comprising:

According to the present invention, there is provided a method for confirming the first bacteria, further comprising a step of adjusting sterilization conditions in the cap sterilization device based on the result of the verification.

The present invention is a method for confirming the first onset of bacteria, wherein the contents are acidic and the pH of the medium is set to 3.5 or more and 4.6 or less.

The present invention is a method for confirming the first onset of bacteria, wherein the contents are neutral and the pH of the medium is set to 6 or more and 8 or less.

Advantageous Effects of Invention According to the present invention, it is possible to grasp the first germs attached to a container or a cap.

FIG. 1 is a schematic plan view showing a content filling system used in a method for confirming the first bacterial outbreak according to one embodiment of the present invention. FIG. 2 is a flow diagram showing a method for confirming the first bacterial infection according to one embodiment of the present invention; FIG. 3 is a schematic plan view showing a content filling system when executing a method for confirming the first bacterial outbreak according to one embodiment of the present invention; FIG. 4 is a flow chart showing a method for confirming the first bacteria according to a modification; FIG. 5 is a schematic cross-sectional view showing a sterilization device of a content filling system used in a method for confirming the first germs.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings. 1 to 3 are diagrams showing one embodiment of the present invention.

(content filling system)
First, the 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 for filling a bottle (container) 30 with content such as a beverage. The bottle 30 can be made by biaxially stretching blow molding a preform made by injection molding a synthetic resin material. As a material for 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 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 rinser 14, a sterile water rinser 15, a filling device (filler) 20, and a capping device (capper). , a seaming and capping machine) 16 and a product bottle delivery section 22 . Along the conveying direction of these bottle supply unit 21, sterilizer 11, air rinse unit 14, sterile water rinse unit 15, filling unit 20, cap mounting unit 16, and product bottle unloading unit 22, from the upstream side to the downstream side. They are arranged in order of leverage. Between the sterilizing device 11, the air rinsing device 14, the sterile water rinsing device 15, the filling device 20, and the capping device 16, a plurality of conveying wheels 12 are provided for conveying the bottles 30 between these devices. there is

The bottle supply unit 21 sequentially receives empty bottles 30 from the outside into the contents filling system 10 and conveys the received bottles 30 toward the sterilization device 11 .

A bottle molding section (not shown) that molds the bottles 30 by biaxially stretch blow molding a preform may be provided upstream of the bottle supply section 21 . In this manner, the steps from supplying the preform to molding the bottle 30, filling the bottle 30 with the contents, and closing the cap may be performed continuously. In this case, it is possible to transport from the outside to the content filling system 10 in the form of a preform with a small volume rather than in the form of a bottle 30 with a large volume, so transportation costs can be reduced.

The sterilizer 11 sterilizes the inside of the bottle 30 by injecting a sterilizing agent into the bottle 30 . This sterilizes the bottle 30 with a sterilizing agent prior to filling with contents, allowing the survival of bacterial spores but not the survival of bacterial vegetative cells, molds and yeasts. As the disinfectant, for example, an aqueous hydrogen peroxide solution is used. In the sterilization device 11 , mist or gas of the 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 by mist or gas of the aqueous hydrogen peroxide solution in this manner, the inner surface of the bottle 30 is sterilized evenly.

The air rinsing device 14 supplies sterile heated air or normal temperature air to the bottle 30 to remove foreign matter, hydrogen peroxide, etc. from the inside of the bottle 30 while activating the hydrogen peroxide.

The sterile water rinsing device 15 is for washing the bottles 30 sterilized with hydrogen peroxide, which is a sterilizing agent, with sterile water of 15°C to 85°C. As a result, hydrogen peroxide adhering to the bottle 30 is washed away and foreign matter is removed.

In addition, in this embodiment, the container sterilization device 13 is configured by the sterilization device 11 described above.

The filling device 20 fills the contents sterilized in advance into the bottle 30 from the mouth of the bottle 30 . In this filling device 20, an empty bottle 30 is filled with contents. In the filling device 20, the contents are filled into the bottles 30 while the plurality of bottles 30 are being rotated (revolved). This content may be filled in the bottle 30 at room temperature. The contents are previously sterilized by heating or the like, cooled to room temperature of 3° C. or more and 40° C. or less, and then filled into the bottle 30 . Bacterial spores are allowed to survive in bottle 30 as described above. For this reason, it is possible to fill the bottle 30 with the content heated to a high temperature, hold the content in the bottle 30 for a long time after filling the bottle 30, or fill the bottle 30 and close it with the cap 33. There is no need to sterilize the bottle 35 (described later) by heating it from the outside.

By the way, the contents filled from the filling device 20 have predetermined characteristics that affect the growth of bacteria. In this embodiment, the predetermined characteristic may be the pH of the contents. More specifically, the contents may consist of an acidic beverage. The acidity of the beverage is preferably below pH 4.6, more preferably below pH 4.0. Beverages with a pH of 4.0 or higher and pH 4.6 or lower include, for example, tomato juice and vegetable juice. There are lemon juice, grape juice, fruit juice and so on.

In general, bacterial spores remain bacteriostatic without germinating in liquids with a relatively high acidity (e.g., pH less than 4.6, preferably less than 4.0), which causes spoilage of the contents. saved without Therefore, as described above, the bacterial spores remain alive in the bottle 30 before being filled by the filling device 20, but germination of the bacterial spores can be suppressed (for example, the pH is less than 4.6, preferably Filling the bottle 30 with pasteurized contents having an acidity of less than 4.0 prevents the beverage from spoiling or spoiling.

The cap attaching device 16 closes the bottle 30 by attaching a cap 33 to the mouth of the bottle 30 . In the capping device 16, the mouth of the bottle 30 is closed by a cap 33, and the inside of the bottle 30 is sealed so that external air and microorganisms do not enter. In the cap attaching device 16, caps 33 are attached to the openings of a plurality of bottles 30 filled with contents while rotating (revolving). By attaching the cap 33 to the mouth of the bottle 30 in this way, the product bottle 35 is obtained.

The cap 33 is sterilized in advance by the cap sterilizer 18 . The cap sterilizer 18 is located, for example, inside a sterile chamber 70 (discussed below) and near the capping device 16 . In the cap sterilizing device 18 , a large number of caps 33 brought in from outside the content filling system 10 are collected in advance and conveyed in a line toward the cap attaching device 16 . On the way to the cap fitting device 16, the cap 33 is sprayed with hydrogen peroxide mist or gas toward the inner and outer surfaces of the cap 33, then dried with hot air and sterilized.

The product bottle unloading section 22 continuously unloads the product bottles 35 attached with the caps 33 by the cap attaching device 16 to the outside of the content filling system 10 .

Note that the content filling system 10 has an aseptic chamber 70 . Aseptic chamber 70 accommodates sterilizer 11 , air rinser 14 , sterile water rinser 15 , filling device 20 , cap sterilizer 18 , and capping device 16 described above. Such a content filling system 10 may comprise, for example, an aseptic filling system. In this case, the interior of the sterile chamber 70 is kept sterile.

Alternatively, the contents filling system 10 may be a hot filling system that fills contents at a high temperature of 85°C or higher and less than 100°C. Alternatively, it may be a medium-temperature filling system in which contents are filled at a medium temperature of 55°C or more and less than 85°C. On the other hand, the technical idea according to this embodiment can also be applied to aseptic packaging using post-sterilization such as retort sterilization.

(Content filling method)
Next, a content filling method using the content filling system 10 (FIG. 1) described above will be described. In addition, below, the filling method in the normal time, that is, the content filling method of actually filling the bottle 30 with the content such as a beverage to manufacture the product bottle 35 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 section 21 . The bottle 30 is sent from the bottle supply unit 21 to the sterilizer 11 by the transport wheel 12 (container supply step).

Next, in the sterilization device 11 constituting the container sterilization device 13, the bottle 30 is sterilized using an aqueous hydrogen peroxide solution as a sterilization agent (sterilization step). At this time, the aqueous hydrogen peroxide solution is gas or mist once vaporized at a boiling point or higher, and is supplied toward the bottle 30 . The mist of the aqueous hydrogen peroxide solution adheres to the entire inner surface of the bottle 30 and kills vegetative cells of bacteria, mold and yeast within the bottle 30 . The amount of hydrogen peroxide mist supplied into the bottle 30 is, for example, 5 μL/bottle or more and 50 μL/bottle or less, and in the case of hydrogen peroxide gas, it is 1 mg/L or more and 5 mg/L or less. The force kills bacterial vegetative cells, molds and yeasts, but not bacterial spores. This makes it possible to reduce the amount of hydrogen peroxide used.

Subsequently, the bottle 30 is sent to the air rinsing device 14 by the conveying wheel 12, and in the air rinsing device 14, the hydrogen peroxide is activated by supplying sterile heated air or normal temperature air, and the foreign matter is removed from the bottle 30 while activating the hydrogen peroxide. , hydrogen peroxide, etc. are removed. Bottles 30 are then transported by transport wheel 12 to sterile water rinse device 15 . In this sterile water rinsing device 15, cleaning with sterile water of 15° C. to 85° C. is performed (rinsing step). Specifically, sterile water of 15° C. to 85° C. is supplied into the bottle 30 at a flow rate of 5 L/min or more and 15 L/min or less. At this time, preferably, the bottle 30 is placed in an inverted state, and sterile water is supplied into the bottle 30 from the mouth facing downward, and this sterile water flows out of the bottle 30 from the mouth. The warm water washes away hydrogen peroxide adhering to the bottle 30 and removes foreign substances.

The bottles 30 are then transported to the filling device 20 by the transport wheels 12 . In the filling device 20, the bottle 30 is rotated (revolved) while contents are filled into the bottle 30 from its mouth (filling step).

Before the bottle 30 is filled with the filling device 20, the contents are prepared in advance and heat sterilized. As noted above, the contents may have a predetermined pH, a property that affects bacterial growth. Specifically, the content may consist of an acidic beverage, preferably below pH 4.6, more preferably below pH 4. The heating temperature is generally about 60° C. or more and 120° C. or less when the acidity of the contents is less than pH 4.0, and about 115° C. or more and 150° C. or less when the pH is 4.0 or more. This sterilizes all microorganisms that may grow inside the product bottle 35 in the contents before filling. The heat-sterilized contents are cooled to a normal temperature of about 3°C or higher and 40°C or lower.

In the filling device 20, the sterilized bottle 30 is filled at normal temperature with the contents that have been sterilized and cooled to normal temperature. The temperature of the contents during filling is, for example, about 3° C. or higher and 40° C. or lower. The acidity of the contents is preferably less than pH 4.6, more preferably less than pH 4, as described above. Sex drinks, carbonated lemon juice, grape juice, fruit juice and the like. That is, according to such a content filling method, it is possible to manufacture the product bottle 35 filled with almost all types of beverages except for barley tea, mixed tea, and milk-containing beverages having a pH of 4.6 or higher. Needless to say, product bottles 35 of carbonated beverages such as cola and cider that do not contain animal or plant components and have a carbon dioxide pressure of 1.0 kg/cm@2 (20.degree. C.) or higher can also be manufactured.

Subsequently, the filled bottle 30 is transported to the capping device 16 by the transport wheel 12 .

On the other hand, the cap 33 is sterilized in advance 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 sterilizer 18 to sterilize its inner and outer surfaces, dried with hot air, and sent to the cap attaching device 16 .

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

After that, the product bottle 35 is conveyed from the cap attaching device 16 to the product bottle unloading section 22 and unloaded to the outside of the content filling system 10 .

Each step from the sterilization step to the cap attaching step is performed in a sterile atmosphere surrounded by the sterile chamber 70, that is, under a sterile environment. The inside of the aseptic chamber 70 is sterilized in advance by spraying hydrogen peroxide, spraying hot water, etc. so as to allow the survival of bacterial spores but not the survival of bacterial vegetative cells, molds and yeasts. After the sterilization process, positive-pressure aseptic air is supplied into the aseptic chamber 70 so that the aseptic air is always blown out of the aseptic chamber 70 .

The production (conveyance) speed of the bottles 30 in the content filling system 10 is preferably 100 bpm or more and 1500 bpm or less. Here, bpm (bottle per minute) means the transport speed of the bottle 30 per minute.

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

The first germ confirmation method according to the present embodiment confirms whether or not the sterility of the bottle 30 to be filled with contents in the contents filling system 10 is ensured. This method of confirming the initial bacteria is, for example, at an initial stage immediately after the contents filling system 10 is completed, that is, before actually filling the bottles 30 using the contents filling system 10 and starting the production of the product bottles 35. may be performed. Alternatively, the first bacteria confirmation method according to the present embodiment can affect sterility when there is some change in the process or device in the content filling system 10, or when the content filling system 10 has not been used for a certain period of time. may be performed when there is a risk of causing Alternatively, the method for confirming the initial germ formation may be performed periodically for each predetermined filling cycle regardless of whether or not there is a risk of affecting sterility.

First, before carrying out the method for confirming the first bacteria according to the present embodiment, individual components of the content filling system 10 are individually tested to determine whether sterility is ensured. Specifically, for example, a test of whether or not the temperature of the supply line of the contents is correctly raised (SIP temperature rise confirmation test), a test of whether or not the bottle 30 and the cap 33 are correctly sterilized (bottle sterilization test). , cap sterilization test), and a test of whether or not the sterile chamber 70 is sterilized (chamber sterilization test).

After such a test is performed, the method for confirming the first germs according to the present embodiment is executed in order to evaluate the sterility of the bottle 30 . Specifically, a large number of bottles 30 are flowed into the content filling system 10, and instead of sterilizing the bottles 30 by the container sterilization device 13 (sterilization device 11), each bottle 30 is filled with the content actually filled. Then, it is filled with a predetermined culture medium and closed with a cap 33 . Thereafter, after a certain period of time has elapsed, it is confirmed that the medium filled in each bottle 30 has not spoiled (method for confirming the initial bacteria on the container).

Hereinafter, a method for confirming the first bacteria (confirming method for the first bacteria in a container) of the content filling system 10 according to the present embodiment will be further described with reference to FIGS. 2 and 3. FIG. FIG. 2 is a flow diagram showing the method for confirming the first germs according to the present embodiment, and FIG. 3 is a schematic plan view showing a content filling system when executing the method for confirming the first germs according to the present embodiment. In FIG. 3, the same reference numerals are given to the same parts as those of the contents 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 step, step S1 in FIG. 2). The number of bottles 30 is predetermined, and can be, for example, 100 or more and 300,000 or less (preferably 1,000 or more and 30,000 or less).

The bottles 30 are then sent to the sterilizer 11 of the container sterilizer 13 . The sterilizer 11, the air rinser 14, and the sterile water rinser 15 of the container sterilizer 13 are stopped in advance, and the bottles 30 are not sterilized. Therefore, without sterilizing the bottles 30 by the sterilizing device 11, the bottles 30 pass through the sterilizing device 11, the air rinsing device 14, and the aseptic rinsing device 15 as they are and are conveyed to the filling device 20 (non-sterilized container conveying step, Step S2 in FIG. 2). Instead of passing through the sterilizer 11, the air rinser 14 and the aseptic rinser 15, the bottles 30 may be sent to the filling device 20 using another detour route.

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 is bypassed so as not to introduce the hydrogen peroxide gas into the bottle 30, or the supply of the hydrogen peroxide gas is stopped. In addition, if air is supplied into the bottle 30, the number of initially generated bacteria in the bottle 30 cannot be accurately measured, so it is necessary to bypass the air.

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

Another strut 58 extends upward from the board surface of the wheel 51, and a gripper 60 for the bottle 30 is attached to the upper part of this strut 58. As shown in FIG. A large number of struts 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 struts 58 and rotate with the rotation of the wheel 51 .

A hydrogen peroxide gas supply pipe 59 extends from around the manifold 55 toward each gripper 60 , and a nozzle 61 is attached to the tip of each supply pipe 59 . The nozzle 61 is fixed to the support 58 , and the opening at the tip of the nozzle 61 faces the mouth of the bottle 30 held by the gripper 60 . As a result, when the wheel 51 rotates, the nozzle 61 rotates around the pivot shaft 53 together with the bottle 30 held by the gripper 60 to spray hydrogen peroxide gas onto the bottle 30 . A tunnel 62 is provided around the wheel 51 so as to enclose 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 integral with the manifold 55 and rotates with respect to the conduit 63, and a seal member 64 prevents leakage of hydrogen peroxide gas from the connection between the two conduits 56,63. Conduit 63 is fitted with a first valve 41 that controls the passage of hydrogen peroxide gas through conduit 63 . A bypass conduit 67 branches off from the upstream side of the first valve 41 . A bypass conduit 67 communicates with the interior of the sterile chamber 70 . A second valve 43 is attached to the bypass conduit 67 to control passage of hydrogen peroxide gas through the bypass conduit 67 . Incidentally, the bypass conduit 67 may extend from between the bearing 57 and the nozzle 61 .

A gas supply device comprising 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 . A hydrogen peroxide addition device 68 is incorporated in one or both of the front and rear of the electric heater 69 . When the hydrogen peroxide addition device 68 is installed downstream of the electric heater 69, it is preferable to mix the hydrogen peroxide gas into the piping. If the hydrogen peroxide is not in the gaseous state, the residual value of hydrogen peroxide tends to increase. On the other hand, when the hydrogen peroxide adding device 68 is installed upstream of the electric heater 69, the hydrogen peroxide may be added in a liquid form such as a spray into the pipe. In that case, the set temperature of the electric heater 69 is preferably set to the boiling point or higher of the sterilizing agent to be supplied, but may be set to 100° C. or higher (preferably 130° C. or higher) according to the sterilization strength of the bottle 30 . Alternatively, another electric heater may be provided further upstream of the spray to spray sterile hot air (80° C. or higher). Alternatively, the hydrogen peroxide adding 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 likely to be adsorbed and the residual value tends to increase. 1/20, which is extremely small. Therefore, in addition to the method of gasifying the hydrogen peroxide solution and adding it to the sterilized air, the method of spraying the hydrogen peroxide solution and mixing it may be adopted. This hydrogen peroxide gas passes through each supply pipe 59 and blows out from the nozzle 61 to the bottle 30 to sterilize the bottle 30 . A pressure gauge 71 for measuring the pressure inside the sterile chamber 70 is attached to the sterile chamber 70 . Also, the sterilizing agent may contain hydrogen peroxide at a concentration of 1% or more. 35% hydrogen peroxide water diluted with ethanol may also be used.

Referring to FIG. 5, during normal production, the first valve 41 of the sterilizer 11 is open and the second valve 43 is closed so that hydrogen peroxide gas is allowed to flow through the commonly used conduit 63 to the bottles 30 . introduced within. On the other hand, when confirming the initial bacteria on the container, the first valve 41 is closed and the second valve 43 on the bypass side is opened. As a result, the hydrogen peroxide gas passes through the bypass conduit 67 and is not introduced into the bottle 30 . When confirming the initial bacteria in the container, the first valve 41 may be opened and the second valve 43 on the bypass side may be opened.

In the subsequent air rinsing process by the air rinsing device 14, similarly, it is necessary to bypass the sterile air or stop the supply of sterile air so as not to replace the inside of the bottle 30 with sterile air. However, it is preferable to supply aseptic air to the aseptic chamber 70 in the same manner as in normal manufacturing so that germs do not enter the aseptic chamber 70 under positive pressure. In addition, the configuration of the air rinse device 14 may be substantially the same as that of the sterilization device 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, it is not possible to accurately determine the initial number of bacteria. flow rate must be reduced. If the machine is run dry with the sterile water rinse stopped, the distributor of the sterile water rinse device 15 may wear and break, so it is preferable to minimize the flow rate while supplying sterile water. The same idea should be applied to the chemical rinse method using peracetic acid preparation.

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

Before the bottle 30 is filled with the filling device 20, the culture medium is prepared in advance and heat sterilized. The characteristics of this medium are the characteristics of the contents to be filled in the contents filling system 10, and are matched to 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 content, 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 the upper limit of pH 4.0. Moreover, when the pH of the content is pH 4 or more and less than 4.6, the pH of the medium is preferably adjusted to the upper limit of pH 4.6. On the other hand, when the specification of the product with 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 changed to pH 3.5, or the upper limit of pH 3.7, or A sterility verification test may be performed after adjusting the pH to 3.8 or 3.9, which is slightly above the upper limit.

In this way, by adjusting the medium to the characteristics of the contents and adjusting the pH to 3.5 or more and 4.6 or less, preferably 4.0 or more and 4.6 or less, the medium is suitable for survival of bacterial spores. The environment is permissive for vegetative cells of bacteria, but not for the survival of molds and yeasts. For this reason, the growth environment of bacteria in the medium can be brought closer to the content that is actually filled.

Such a medium generally contains monosaccharides, disaccharides, and polysaccharides such as organic carbon sources such as glucose and dextrose as carbon sources, and sodium carbonate and sodium bicarbonate as inorganic carbon sources in an amount of 0.2 to 20%. 3% by weight and 0.5 to 0.5% of nitrogen sources (including coenzymes) such as casein peptone, chicken peptone, heart muscle peptone, gelatin peptone, soybean peptone, polypeptone, yeast extract, meat extract, ammonium sulfate, magnesium sulfate, nitrate, etc. Prepared by dissolving in water 3% by weight and 0.05-1% by weight of trace minerals or buffers such as sodium chloride, monopotassium phosphate, potassium monohydrogen phosphate, potassium dihydrogen phosphate, etc. 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 culture medium is sterilized by heating (UHT) or filtration by a predetermined sterilization method in the liquid processing facility 23 and filled in the filling device 20 . When carbonated beverages are also produced in the liquid processing equipment 23, it is necessary to install a carbon dioxide dissolving device (carbonator) 24 in front of the filling device 20 for adding filter-sterilized carbon dioxide to the product liquid. If carbon dioxide gas is added when filling the medium, the medium may become bacteriostatic, so it is recommended to stop the supply of carbon dioxide gas or replace the carbon dioxide gas with air. By changing the carbon dioxide gas to air, it becomes possible to confirm the sterility of the equipment including the filtration filter of the carbon dioxide gas aseptic equipment (not shown).

Subsequently, the bottle 30 filled with the culture medium is sent from the filling device 20 to the capping device 16 through the gas replacement device 25 that replaces the gas in the head space in the bottle 30 . The gas replacement device 25 blows an inert gas (nitrogen or carbon dioxide) sterilized by filtration into the mouth of the bottle 30 during normal production, but when filling the medium, the inert gas (nitrogen or carbon dioxide) ) or replace the inert gas with air. By changing to air, it is also possible to confirm the sterility of the headspace including the filtration filter of the gas replacement device 25 .

On the other hand, the cap 33 is sterilized in advance by the cap sterilizer 18 (cap sterilization step, step S8 in FIG. 2). The cap 33 is brought into the cap sterilizer 18 from the outside of the content filling system 10, sprayed with hydrogen peroxide mist or gas to sterilize the inner and outer surfaces, and activate the hydrogen peroxide with hot air. It is removed, washed with sterile water, and sent to capping 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, the cap attaching device 16 attaches the sterilized cap 33 sterilized by the cap sterilizing device 18 to the mouth of the bottle 30 (cap attaching step, step S4 in FIG. 2). This cap fitting process is performed in the same manner as the cap fitting process in the above-described normal contents filling method. In this manner, the inside of the bottle 30 is filled with culture medium, and the opening is sealed with the cap 33 to obtain the verification bottle 36 .

Next, the verification bottle 36 filled with the culture medium is carried outside from the product bottle carry-out section 22 and packed in a packaging process. The boxed cases are manually or automatically tilted (or inverted) on the conveyor to ensure contact of the culture medium with the inner surfaces of the bottles 30 (medium contact step, step S5 in FIG. 4). After that, the plurality of verification bottles 36 are transported to a constant temperature chamber 37 maintained at a predetermined temperature of 25° C. or more and 40° C. or less, and left standing in this constant temperature chamber 37 to be cultured (cultivation step, step in FIG. 2 S6). When the product bottle 35 is heated and sold by a hot vendor or the like, it is desirable to check the sterility of 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) has passed, all the verification bottles 36 are taken out from the constant temperature chamber 37, and it is verified whether or not the bacteria have survived or propagated in the medium in the verification bottles 36. (verification step, step S7 in FIG. 2). As a result of this verification, if the number of verification bottles 36 in which bacteria have survived or propagated is equal to or less than a predetermined number (for example, zero), it is determined that the bottle 30 has no initial bacteria and is aseptic. On the other hand, if the number of verification bottles 36 in which the bacteria survived or propagated exceeds a predetermined number (for example, one or more) as a result of the verification, it is determined that the first bacteria have occurred in the bottles 30, and countermeasures are taken. For example, it is possible to sterilize the conveying and carrying-in routes of the bottles 30, or prepare (strengthen) the sterilization conditions in the container sterilizer 13 (sterilizer 11). In some cases, depending on the type of bacteria, the bottle 30 can be sufficiently sterilized by operating the container sterilization device 13 (sterilization device 11). At this time, it can be determined that it is sufficient to activate the container sterilizer 13 .

As described above, according to the present embodiment, after the bottle 30 which is not sterilized by the container sterilizer 13 is filled with culture medium and closed with the cap 33, bacteria survive or grow in the culture medium in the bottle 30. Verify whether or not there is As a result, it is possible to accurately grasp the bioburden of the bottle 30 as to whether or not the first germs are generated, and to take measures to sterilize the bottle 30 before actually filling the bottle 30 with contents such as beverages. can be done.

In addition, according to the present embodiment, the pH of the medium used for verification is set to 4.0 or more and 4.6 or less in accordance with the acid content that is actually filled. It is designed to allow the survival of spores while not allowing the survival of bacterial vegetative cells, molds and yeasts. As a result, when comprehensively evaluating the sterility of the contents filling system 10 using the culture medium, it is possible to verify the growth environment of bacteria in a state that is close to the actual contents. As a result, it is possible to reduce the amount of chemicals and heat energy required for sterilization, thereby reducing the manufacturing cost of the product bottle 35 . For example, to reduce the temperature of steam, hot water, etc. used when performing SIP (Sterilizing in Place) processing in the beverage supply system piping of the content filling system 10, or to shorten the flow time of steam, hot water, etc. can be done. In addition, the time required for COP (Cleaning out of Place) processing or SOP (Sterilizing out of Place) processing in the aseptic chamber 70 can be shortened.

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

In the above description, the case of using a sterilization device that performs hydrogen peroxide sterilization and hot water sterilization as a container sterilization device has been described, but the present invention is not limited to this. There is a peracetic acid sterilization method in which the inner and outer surfaces of the bottle are sterilized with peracetic acid rinse, and then the inner and outer surfaces are rinsed with sterile water, and an electron beam is irradiated from the inner or outer surface of the bottle to sterilize the bottle, followed by air 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. Also, in the above description, the case where a PET bottle is used as a container is used as an example, and a culture medium for aerobic bacteria is used as a culture medium, but the invention is not limited to this. When using a retort container such as canned food, a medium for anaerobic bacteria may be used as the medium.

(Modification)
Next, a modified example of this embodiment will be described.

In the embodiment described above, the case of verifying whether or not the bottle 30 has the first germs has been described as an example. However, it is not limited to this, and it may be verified whether or not the cap 33 has the first bacteria. That is, a large number of bottles 30 are passed through the contents filling system 10, and after each bottle 30 is sterilized, each bottle 30 is filled with a predetermined culture medium instead of the contents actually filled. Next, the bottle 30 is capped with a cap 33 that has not been sterilized by the cap sterilizer 18 . Thereafter, it is confirmed that the culture medium filled in each bottle 30 does not rot after a certain period of time has passed (method for confirming the first bacteria on the cap).

Hereinafter, a method for confirming the first germs (a method for confirming the first germs on the cap) of the content filling system 10 according to the present modification will be described with reference to FIGS. 3 and 4. FIG. FIG. 4 is a flow diagram showing a method for confirming the first bacteria according to the modification.

First, an empty bottle 30 for verification is passed through the content filling system 10 in the same manner as described above. 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 step, step S11 in FIG. 4). The number of bottles 30 is predetermined, and can be, 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 sterilizer 11 of the container sterilizer 13, and in this sterilizer 11, the bottle 30 is sterilized using an aqueous hydrogen peroxide solution as a sterilizing agent (sterilization step, Step S12 in FIG. 4). This sterilization step is performed in the same manner as the sterilization step in the above-described normal contents filling method.

Subsequently, the bottle 30 is sequentially sent to the air rinsing device 14 and the sterile water rinsing device 15, and in the air rinsing device 14 and the sterile water rinsing device 15, the bottle 30 is cleaned with air and sterile water (rinsing). process, step S13 in FIG. 4). This rinsing step is the same as the rinsing step in the normal content filling method described above.

Bottles 30 are then conveyed to filling device 20 . In this filling device 20, a predetermined amount of sterilized culture medium is filled into the bottle 30 through the mouth of the bottle 30 (medium filling step, step S14 in FIG. 4). In addition, this medium filling step is the same as the medium filling step in the above-described method for confirming the first bacteria on the container.

On the other hand, the cap sterilizer 18 is stopped in advance, and the cap 33 is not sterilized. Therefore, the cap 33 passes through the cap sterilizing device 18 without being sterilized by the cap sterilizing device 18 and is conveyed to the cap mounting device 16 (unsterilized cap conveying step, step S18 in FIG. 4). It should be noted that instead of passing through the cap sterilizer 18, the caps 33 may be sent to the capping device 16 using another detour route.

The bottle 30 filled with medium is then sent to the capping device 16 . In this cap fitting device 16, a non-sterilized cap 33 is fitted to the mouth of the bottle 30 (cap fitting step, step S15 in FIG. 4). In this manner, the inside of the bottle 30 is filled with the culture medium, and the opening is sealed with the non-sterilized cap 33 to obtain the verification bottle 36 .

Next, the verification bottle 36 filled with the culture medium is carried outside from the product bottle carry-out section 22 and packed in a packaging process. The boxed cases are manually or automatically tilted (or turned over) on the conveyor to ensure contact of the culture medium with the inner surface of the cap 33 (medium contact step, step S16 in FIG. 4). Thereafter, the plurality of verification bottles 36 are transported to the constant temperature chamber 37, where they are allowed to stand and cultured (cultivation step, step S17 in FIG. 4). This culturing step is the same as the culturing step in the above-described method for confirming the first bacteria on the container.

After a predetermined period (for example, 3 days or more and 10 days or less) has passed, all the verification bottles 36 are taken out from the constant temperature chamber 37, and it is verified whether or not the bacteria have survived or propagated in the medium in the verification bottles 36. (verification step, step S18 in FIG. 4). As a result of this verification, it is possible to accurately grasp the bioburden of the actual cap. On the other hand, if the verification result shows that the number of verification bottles 36 in which bacteria have survived or propagated is equal to or greater than a predetermined number (for example, one or more), it is determined that the cap 33 is initially infected with bacteria, and countermeasures are taken. For example, sterilization of the transfer and carry-in routes of the cap 33 may be implemented, or sterilization conditions in the cap sterilization device 18 may be adjusted (enhanced). Depending on the type of bacteria, the cap 33 may be sufficiently sterilized by operating the cap sterilization device 18. It can be determined that it is sufficient if it works.

As described above, according to this modification, after the sterilized bottle 30 is filled with culture medium and capped with the cap 33 that is not sterilized by the cap sterilizer 18, bacteria survive or grow in the culture medium in the bottle 30. Verify whether or not As a result, it is possible to accurately grasp whether or not the cap 33 is initially germinated, and to take measures to sterilize the cap 33 before actually filling the bottle 30 with contents such as beverages.

It should be noted that it is also possible to combine the above-described embodiment and modifications to verify at once whether or not the first germs have occurred on either the bottle 30 or the cap 33 . That is, the bottle 30 is conveyed to the filling device 20 without being sterilized by the container sterilizing device 13, and the filling device 20 is used to fill the unsterilized bottle 30 with the sterilized culture medium. Subsequently, the cap 33 is conveyed to the cap attaching device 16 without being sterilized by the cap sterilizing device 18, and the cap attaching device 16 is used to cap the bottle 30 with the unsterilized cap 33. After that, it may be verified whether or not the bacteria have survived or propagated in the medium in the bottle 30 .

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

(Example 1)
A 600 bpm (bottle per minute) beverage filling system was used in which the sterilized beverages were cold filled into sterile 500 mL PET bottles in an aseptic atmosphere and sealed with sterile caps. Using this beverage filling system, 3000 unsterilized PET bottles were filled with pH 4.0 sterilized acidic medium at room temperature and capped with sterilized caps. Next, these were cultured at 27° C. for 1 week, and then all the PET bottles were inspected. Bacteria contained in this spoiled medium were identified and found to be Cladosporium cladosporioides with low drug resistance. For this reason, it was determined that sufficient sterilization could be achieved by operating the container sterilization device when the PET bottle was actually filled with the beverage.

(Example 2)
A 600 bpm (bottle per minute) beverage filling system was used in which the sterilized beverages were cold filled into sterile 500 mL PET bottles in an aseptic atmosphere and sealed with sterile caps. Using this beverage filling system, 3000 sterilized PET bottles were filled with pH 4.0 sterilized acidic culture medium at room temperature and capped with non-sterilized caps. Next, these were cultured at 27° C. for 1 week, and then all the PET bottles were inspected. When the fungus contained in this rotten medium was identified, it was presumed to be A.niger. For this reason, it was determined that sufficient sterilization could be achieved by operating the cap sterilizer when actually filling a PET bottle with a beverage.

REFERENCE SIGNS LIST 10 content filling system 11 sterilization device 12 conveying wheel 13 container sterilization device 14 air rinse device 15 aseptic rinse device 16 cap mounting device 18 cap sterilization device 20 filling device 21 bottle supply unit 22 product bottle unloading unit 30 bottle 33 cap 35 product bottle 36 Verification bottle 37 Constant temperature chamber 70 Aseptic chamber

Claims (4)

A first bacteria confirmation method using a content filling system having a container sterilization device for sterilizing a container and a filling device for filling the content in the container,
conveying the container to the filling device without sterilizing the container by the container sterilizing device;
using the filling device to fill the container with a medium that has been prepared in advance so as to have a pH that matches the pH of the contents;
sealing the container filled with the medium;
Before starting the culture of the container, tilting or inverting the container filled with the medium to ensure contact of the medium with the inner surface of the container;
a step of verifying whether or not bacteria survive or propagate in the medium in the container ;
The content is acidic, and the medium has a pH of 3.5 or more and 4.6 or less, thereby allowing the survival of bacterial spores but preventing the survival of bacterial vegetative cells, molds and yeasts. is an unacceptable environment . 2. The method for confirming the first germs according to claim 1, further comprising the step of adjusting sterilization conditions in said container sterilizer based on the result of said verification. A first bacteria confirmation method using a contents filling system having a filling device for filling contents into a container, a cap sterilizing device for sterilizing a cap, and a cap mounting device for closing the container with the cap ,
using the filling device to fill the container with a medium that has been prepared in advance so as to have a pH that matches the pH of the contents;
conveying the cap to the cap attaching device without sterilizing the cap by the cap sterilizing device ;
Closing the container with the cap using the capping device;
Before starting the culture of the container, tilting or inverting the container filled with the medium to ensure contact of the medium with the inner surface of the container;
a step of verifying whether or not bacteria survive or propagate in the medium in the container ;
The content is acidic, and the medium has a pH of 3.5 or more and 4.6 or less, thereby allowing the survival of bacterial spores but preventing the survival of bacterial vegetative cells, molds and yeasts. is an unacceptable environment . 4. The method for confirming the first germs according to claim 3, further comprising the step of adjusting sterilization conditions in said cap sterilizer based on the result of said verification.

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