JP7828556B2 - Contents filling system and processing method - Google Patents

Description

This disclosure relates to a content filling system and processing method.

Conventionally, a filling machine installed in a content filling system has been used to continuously and aseptically fill numerous plastic bottles being transported at high speed with beverages and other contents. In such a content filling system, the filling nozzle for filling the plastic bottles is rotatably positioned within a sterile chamber. (See, for example, Patent Documents 1 and 2).

Japanese Patent Publication No. 2007-302325 Japanese Patent Publication No. 2010-006429 Official Gazette No. Showa 60-116337

Conventionally, the flow paths through which the contents pass in a content filling system are cleaned periodically or when switching between types of products being manufactured using a Cleaning in Place (CIP) process. Furthermore, a Sterilizing in Place (SIP) process is performed to sterilize the flow paths. The CIP process is carried out by flowing a cleaning solution, for example, water with an alkaline agent added, through the flow path from the pipes of the beverage supply system to the filling nozzle of the filling machine, either before or after. Examples of alkaline agents include caustic soda (sodium hydroxide), potassium hydroxide, sodium carbonate, sodium silicate, sodium phosphate, or sodium hypochlorite. Examples of acidic agents include nitric acid, phosphoric acid, or organic acids. Surfactants and defoamers may also be added to the cleaning solution. The SIP process is a treatment to sterilize the flow path before the product filling operation begins. For example, high-temperature sterilization is performed by flowing heated steam or hot water through the flow path that has been cleaned using the CIP process. Patent Document 3 discloses a plate-type heat exchanger for sterilization in which the processing liquid is flowed in the opposite direction to the product flow direction.

This disclosure provides a content filling system and a processing method that can improve the cleanability during the cleaning process of the content filling system.

The embodiments of this disclosure relate to the following [1] to [14].

[1] A content filling system for filling contents, comprising: a content sterilization device for sterilizing the contents; a filling device for filling the contents sterilized by the content sterilization device; and a control unit for controlling the content filling system, wherein the content sterilization device comprises a heat exchange unit including at least one heat exchanger and a heating unit connected to the heat exchange unit, the heat exchange unit having a first inlet, a first outlet communicating with the first inlet, a second inlet, and a second outlet communicating with the second inlet, the first outlet and the second inlet being connected via the heating unit, and the control unit performing a forward flow process in which the processing fluid passes through the first inlet, the first outlet, the heating unit, the second inlet, and the second outlet in that order, and a reverse flow process in which the processing fluid passes through the second outlet, the second inlet, the heating unit, the first outlet, and the first inlet in that order.

[2] The contents sterilization device is the contents filling system according to [1], comprising a holding tube.

[3] The contents filling system according to [1] or [2], further comprising a temperature adjustment unit for adjusting the temperature of the contents sterilized in the contents sterilization device to the filling temperature.

[4] The control unit performs the cleaning process in the order of forward flow processing, reverse flow processing, and forward flow processing, as described in any one of [1] to [3].

[5] The contents filling system according to any one of [1] to [4], wherein the processing fluid is heated by the heating unit during the forward flow processing and the reverse flow processing.

[6] The contents filling system according to any one of [1] to [5], further comprising a first tank connected to the contents sterilization device.

[7] The contents filling system according to [6], further comprising a circulation pipe connecting the position between the contents sterilization device and the filling device to the first tank.

[8] The contents filling system according to [7], wherein an additional heat exchanger is provided in the circulation piping, the first tank is connected to the contents sterilization device via the contents supply system piping, and the additional heat exchanger performs heat exchange between the processed fluid flowing through the contents supply system piping and the processed fluid flowing through the circulation piping.

[9] The contents filling system according to [2], wherein the fluid delivery pressure of the processing fluid passing after the holding tube within the heat exchange unit is higher than the fluid delivery pressure of the processing fluid passing before the holding tube.

[10] A processing method for cleaning or sterilizing a contents filling system for filling contents, wherein the contents filling system comprises a contents sterilization device for sterilizing the contents, and a filling device for filling the contents sterilized by the contents sterilization device, the contents sterilization device having a heat exchange unit including at least one heat exchanger, and a heating unit connected to the heat exchange unit, the heat exchange unit having a first inlet, a first outlet communicating with the first inlet, a second inlet, and a second outlet communicating with the second inlet, and the processing method comprising a forward flow processing step of passing a processing fluid through the first inlet, the first outlet, the heating unit, the second inlet, and the second outlet in that order, and a reverse flow processing step of passing the processing fluid through the second outlet, the second inlet, the heating unit, the first outlet, and the first inlet in that order.

[11] The cleaning method according to [10], wherein the cleaning process is performed in the order of the forward flow treatment step, the reverse flow treatment step, and the forward flow treatment step.

[12] The processing method according to [10] or [11], wherein the final step of the processing method is the forward flow processing step.

[13] A treatment method according to any one of [10] to [12], comprising: an alkaline cleaning treatment step which is the forward flow treatment step or the reverse flow treatment step; and an acidic cleaning treatment step which is the forward flow treatment step or the reverse flow treatment step, wherein the alkaline cleaning treatment step is performed before or after the acidic cleaning treatment step, and no water rinsing treatment is performed between the alkaline cleaning treatment step and the acidic cleaning treatment step.

[14] The treatment method according to [13], wherein the alkaline cleaning step is performed immediately after the acidic cleaning step, or the acidic cleaning step is performed immediately after the alkaline cleaning step, and the difference between the pH of the treatment fluid used in the alkaline cleaning step and the pH of the treatment fluid used in the acidic cleaning step is 8 or more and 12 or less.

According to this disclosure, the cleanability during the cleaning process of the contents filling system can be improved.

Figure 1 is a schematic plan view showing a content filling system according to one embodiment. Figure 2 is a schematic diagram showing a content sterilization device for a content filling system according to one embodiment, and the flow path around it. Figure 3 is a schematic cross-sectional view showing the heat exchanger of the heat exchange unit. Figure 4 is a schematic diagram showing the flow of the processed fluid during forward flow treatment. Figure 5 is a schematic diagram showing the flow of the processed fluid during backflow treatment. Figures 6(a)-(e) are tables showing the processing patterns for washing and sterilization treatments. Figures 7(a)-(c) are tables showing the processing patterns for washing and sterilization treatments.

The following description of one embodiment will be given with reference to Figures 1 to 7. Figures 1 to 7 are diagrams illustrating one embodiment. Note that in the following figures, the same parts are denoted by the same reference numerals, and some detailed explanations may be omitted.

(Contents filling system)
First, the overall configuration of the contents filling system (aseptic filling system) according to this embodiment will be explained with reference to Figures 1 and 2.

The content filling system 10 shown in Figure 1 is a system for filling a bottle (container) 90 with contents such as a beverage. The bottle 90 can be manufactured by biaxial stretch blow molding a preform 91 made by injection molding of a synthetic resin material. Alternatively, the bottle 90 may be manufactured by direct blow molding. As the material for the bottle 90, it is preferable to use a thermoplastic resin, particularly PE (polyethylene), PP (polypropylene), PET (polyethylene terephthalate), or PEN (polyethylene naphthalate). Other containers may include glass, cans, paper, pouches, cups, or composite containers thereof. In this embodiment, the case where a synthetic resin bottle is used as the container will be described as an example.

As shown in Figure 1, the contents filling system 10 comprises a contents sterilization device 40, a filling device 20, and a control unit 60. The contents sterilization device 40 pre-sterilizes the contents to be filled into the bottle 90. The filling device 20 fills the bottle with the contents sterilized by the contents sterilization device 40. The control unit 60 controls the contents filling system 10.

The contents filling system 10 further comprises a bottle forming unit 30, a container sterilization device 11, an air rinsing device 14, the aforementioned filling device 20, a capping device (capper, crimping and sealing machine) 16, and a product bottle discharge unit 19. These bottle forming unit 30, container sterilization device 11, air rinsing device 14, filling device 20, capping device 16, and product bottle discharge unit 19 are arranged in this order from upstream to downstream along the direction of bottle 90 transport. Furthermore, multiple transport wheels 12 are provided between the air rinsing device 14, filling device 20, and capping device 16 to transport the bottle 90 between these devices. This section will describe the bottle forming unit 30, container sterilization device 11, air rinsing device 14, filling device 20, capping device 16, and product bottle discharge unit 19.

The bottle molding unit 30 receives the preform 91 from the outside and molds the bottle 90. The bottle molding unit 30 then transports the molded bottle 90 toward the container sterilization device 11. This allows the contents filling system 10 to continuously perform the processes from supplying the preform 91 to molding the bottle 90, filling the bottle 90 with contents, and sealing it. In this case, instead of the larger bottle 90, the smaller volume preform 91 is transported from the outside to the contents filling system 10. Therefore, transportation costs can be reduced. Alternatively, the bottle molding unit 30 may be connected to an injection molding machine (not shown), and the preform 91 may be manufactured from resin pellets. In this case, transportation costs can be further reduced compared to transporting the preform 91 from the outside.

The bottle molding unit 30 includes a preform transport unit 31, a blow molding unit (container molding apparatus) 32, and a bottle transport unit 33. The preform transport unit 31 transports the preform 91. The blow molding unit 32 performs blow molding on the preform 91 sent from the preform transport unit 31, thereby forming a bottle 90 from the preform 91. The bottle transport unit 33 transports the bottles 90 formed in the blow molding unit 32.

The preform transport unit 31 includes a preform receiving unit 34, a preform heating unit 35, and a preform transfer unit 36. Of these, the preform receiving unit 34 receives the preform 91 supplied from the preform supply device 37 via the preform supply conveyor 37a. This preform receiving unit 34 is equipped with a preform sterilization device 34a for sterilizing the preform 91 and a preform air rinsing device 34b for air rinsing the preform 91.

In the preform receiving section 34, the preform sterilization device 34a sprays hydrogen peroxide aqueous solution gas or mist onto the preform 91, thereby sterilizing the preform 91 (preliminary sterilization). The disinfectant used to sterilize the preform 91 can be any disinfectant that inactivates microorganisms. For example, in addition to hydrogen peroxide, peracetic acid, acetic acid, pernitrate, nitric acid, chlorine-based agents, sodium hydroxide, potassium hydroxide, alcohols such as ethyl alcohol and isopropyl alcohol, chlorine dioxide, ozonated water, acidic water, and surfactants may be used individually or in combination of two or more of these.

Thus, by pre-sterilizing the preform 91 using the preform sterilization device 34a (pre-sterilization), the number of bacteria adhering to the bottle 90 produced from the preform 91 can be reduced. Therefore, the amount of hydrogen peroxide used in the container sterilization device 11 for sterilizing the bottle 90 can be reduced, and the sterilization time can be shortened. Generally, the amount of disinfectant used to sterilize the small-volume preform 91 is less than the amount of disinfectant used to sterilize the bottle 90. Therefore, pre-sterilizing the preform 91 reduces the overall amount of disinfectant used.

Furthermore, the amount of hydrogen peroxide used in the container sterilization device 11 can be reduced, and the sterilization time can be shortened, allowing the container sterilization device 11 to be miniaturized. Also, since the sterilization time for sterilizing the bottles 90 can be shortened, the heat load on the bottles 90 can be reduced. Therefore, even with lightweight bottles 90 or bottles 90 made from recycled PET, deformation of the bottles 90 due to the heat of the disinfectant can be suppressed.

Furthermore, this sterilization process may be performed not only in the preform receiving section 34, but also in the preform heating section 35 or the preform transfer section 36. The sterilization process may also be performed after the bottle 90 is formed, between the bottle transport section 33 and the filling device 20. Moreover, the sterilization process may be performed at multiple locations. In addition, instead of using a disinfectant, bacteria may be inactivated by ultraviolet irradiation or electron beam irradiation, etc., during the sterilization process.

Downstream of the preform sterilization device 34a, the preform air rinsing device 34b described above is provided. The preform 91, to which the disinfectant has been sprayed, is dried with hot air in the preform air rinsing device 34b. At this time, it is preferable that the hot air is supplied to the preform 91 with its opening facing downwards. This effectively removes foreign matter from within the preform 91. Therefore, the step of washing the preform 91 with sterile water can be omitted, and the amount of carbon dioxide emitted by the contents filling system 10 can be reduced. Note that the preform air rinsing device 34b is not required in the preform receiving section 34. Furthermore, a foreign matter removal device (not shown) for removing foreign matter adhering to the preform 91 may be provided upstream of the preform sterilization device 34a in the preform receiving section 34.

The preform heating unit 35 is configured to receive the preform 91 from the preform receiving unit 34 and heat the preform 91 while transporting it. This preform heating unit 35 is equipped with a heater 35a for heating the preform 91. This heater 35a may be, for example, an infrared heater. This heater 35a heats the preform 91 to, for example, 90°C to 130°C. The temperature at the opening of the preform 91 is kept below 70°C to prevent deformation.

The preform transfer unit 36 is configured to receive the preform 91, which has been heated by the preform heating unit 35, and transfer it to the blow molding unit 32.

The blow molding section 32 includes a mold (not shown). By blow molding the preform 91 using this mold, the bottle 90 is formed. The formed bottle 90 is then transported downstream by the bottle transport section 33.

Here, a regulating and conveying unit 38 is provided between the bottle molding unit 30 and the container sterilization device 11. This unit receives bottles 90 from the bottle conveying unit 33 and transfers them to the container sterilization device 11. At least a portion of this regulating and conveying unit 38 is housed inside an atmosphere-blocking chamber 70c (described later), which is located upstream of the disinfectant spray chamber 70d (described later). In the illustrated example, the regulating and conveying unit 38 is positioned to straddle the molding chamber 70b (described later), which houses the bottle molding unit 30, and the atmosphere-blocking chamber 70c. By housing at least a portion of the regulating and conveying unit 38 inside the atmosphere-blocking chamber 70c, it is possible to suppress the flow of disinfectant gas, mist, or mixtures thereof generated in the disinfectant spray chamber 70d into the molding chamber 70b.

In the illustrated example, a single transport wheel 12 is provided between the adjustment transport unit 38 and the bottle transport unit 33. That is, the bottle transport unit 33 of the bottle molding unit 30, a single transport wheel 12, and the adjustment transport unit 38 are provided between the blow molding unit 32 of the bottle molding unit 30 and the container sterilization device 11. This allows the contents filling system 10 to be more compact compared to the case where multiple transport wheels 12 are provided between the adjustment transport unit 38 and the bottle transport unit 33 of the bottle molding unit 30. Although not shown, the contents filling system 10 may also be provided only between the blow molding unit 32 of the bottle molding unit 30 and the container sterilization device 11. In this case, the contents filling system 10 can be made even more compact. Furthermore, if the contents are filled while molding is performed in the blow molding unit 32, the contents filling system 10 can be made even more compact.

The container sterilization device 11 is a device that sterilizes bottles 90 by spraying a disinfectant onto them. This sterilizes the bottles 90 with the disinfectant before they are filled with contents. For example, a hydrogen peroxide solution is used as the disinfectant. In the container sterilization device 11, a gas or mist of the hydrogen peroxide solution is generated, and this gas or mist is sprayed onto the inner and outer surfaces of the bottles 90. Because the bottles 90 are sterilized with the hydrogen peroxide solution gas or mist in this way, the inner and outer surfaces of the bottles 90 are sterilized evenly.

The air rinsing device 14 is a device that removes foreign matter and hydrogen peroxide from inside the bottle 90 while activating hydrogen peroxide by supplying sterile heated air or sterile room-temperature air to the bottle 90. In this case, it is preferable that sterile air is supplied to the bottle 90 with the mouth of the bottle 90 facing downwards. This effectively removes foreign matter from inside the bottle 90. Therefore, the step of washing the bottle 90 with sterile water can be omitted, saving water. Furthermore, the amount of carbon dioxide emitted by the contents filling system 10 can also be reduced. If necessary, a low-concentration hydrogen peroxide condensation mist may be mixed with sterile room-temperature air to gasify the hydrogen peroxide and supply it to the bottle 90.

The filling device 20 is a device that fills bottles 90 with the contents of a beverage or the like. That is, the filling device 20 fills the contents into the bottle 90 from the mouth of the bottle 90. In this way, the filling device 20 fills empty bottles 90 with contents. In this filling device 20, multiple bottles 90 are rotated and conveyed while the contents are filled into the inside of the bottles 90. The filling device 20 is located inside the sterile chamber 70f, which will be described later. The filling device 20 may be a so-called rotary filler having multiple rotatable filling nozzles 22, or it may be a filler that conveys bottles 90 in a linear fashion. Further details of the filling device 20 will be described later.

The capping device 16 is a device that seals a bottle 90 by attaching a cap 92 to it. In the capping device 16, the bottle 90 filled with contents is closed with the cap 92. This seals the bottle 90, preventing outside air and microorganisms from entering. In the capping device 16, while holding multiple bottles 90 filled with contents, the cap 92 is rotated (revolved) and attached to the opening of each bottle. By attaching the cap 92 to the bottle 90 in this way, a product bottle 95 is obtained.

The caps 92 are sterilized beforehand by a cap sterilization device 18. The cap sterilization device 18 is located, for example, outside the sterile chamber 70f and near the cap mounting device 16. In the cap sterilization device 18, the caps 92 brought in from outside the contents filling system 10 are collected in advance and transported in a line toward the cap mounting device 16. As the caps 92 proceed toward the cap mounting device 16, hydrogen peroxide gas or mist is sprayed onto the inner and outer surfaces of the caps 92, and then they are dried with hot air for sterilization.

The product bottle discharge unit 19 continuously discharges product bottles 95, with caps 92 attached by the cap attachment device 16, toward the outside of the contents filling system 10.

The contents filling system 10 includes a preform sterilization chamber 70a, a molding chamber 70b, an atmosphere isolation chamber 70c, a disinfectant spray chamber 70d, an air rinse chamber 70e, a sterile chamber 70f, and an outlet chamber 70g. The preform sterilization chamber 70a, molding chamber 70b, atmosphere isolation chamber 70c, disinfectant spray chamber 70d, air rinse chamber 70e, sterile chamber 70f, and outlet chamber 70g are arranged in this order from upstream to downstream along the transport direction of the preform 91 and bottle 90.

Each chamber 70a to 70g is separated by a partition wall. The partition wall prevents the disinfectant or other substance from flowing in unintended directions between chambers 70a to 70g and stabilizes the pressure within each chamber 70a to 70g. A gap sufficient to allow a preform 91 or bottle 90 to pass through is formed in each partition wall. This gap is formed to a minimum size, for example, approximately the size of one preform 91 or bottle 90, to prevent changes in the pressure within each chamber 70a to 70g. Furthermore, a shutter may be provided in the partition wall to close the aforementioned gap. This shutter may be configured to open and close automatically, for example, in response to a signal from the control unit 60.

Of the chambers 70a to 70g, the preform sterilization chamber 70a houses the preform sterilization device 34a, etc. The molding chamber 70b houses the blow molding section 32 of the bottle molding section 30, etc. At least a part of the adjustment and conveying section 38 is housed inside the atmosphere isolation chamber 70c. The disinfectant spray chamber 70d houses the container sterilization device 11. The air rinsing chamber 70e houses the air rinsing device 14. The sterile chamber 70f houses the filling device 20, the conveying wheel 12, and the cap attaching device 16. Furthermore, the product bottle discharge section 19 is housed inside the outlet chamber 70g.

As described above, the contents filling system 10 includes a control unit 60 that controls the contents filling system 10. This control unit 60 is electrically connected to the bottle molding unit 30, the container sterilization device 11, the air rinsing device 14, the filling device 20, the cap attachment device 16, the product bottle discharge unit 19, and the cap sterilization device 18, and may control these devices. This control unit 60 may also clean and sterilize the inside of each chamber. In this embodiment, the control unit 60 cleans the inside of the sterile chamber 70f (cleaning the inside of each chamber is also called COP).

Such a content filling system 10 may consist of, for example, an aseptic filling system. In this case, the insides of the disinfectant spray chamber 70d, the air rinse chamber 70e, the aseptic chamber 70f, and the outlet chamber 70g are maintained in an aseptic state. Furthermore, a chamber (not shown) connecting an aseptic zone and a non-sterile zone may be provided downstream of the outlet chamber 70g.

Next, the configuration of the contents sterilization device 40 and the filling device 20 of the contents filling system 10 will be explained using Figure 2. Figure 2 is a configuration diagram showing the contents sterilization device 40, the filling device 20, and their surroundings within the contents filling system 10 described above.

As shown in Figure 2, the contents filling system 10 comprises a contents sterilization device 40 and a filling device 20. The contents filling system 10 further comprises a contents mixing unit 41, a first tank 42, a temperature control unit 43, and a second tank 44.

The contents mixing unit 41, the first tank 42, the contents sterilization device 40, the temperature control unit 43, and the second tank 44 are connected by contents supply system piping 45a to 45d. During filling, the contents, such as beverages, sequentially pass through the contents supply system piping 45a to 45d. During the cleaning process (CIP process), a processing fluid, such as a rinse solution, alkaline cleaning solution, or acidic cleaning solution, is flowed through the contents supply system piping 45a to 45d. During the sterilization process (SIP process), for example, a processing fluid such as heated steam or hot water is flowed through the contents supply system piping 45a to 45d, which has been cleaned by the CIP process, thereby performing high-temperature sterilization. In this specification, the processing fluid may be any of the following: rinse solution, alkaline cleaning solution, acidic cleaning solution, heated steam, or hot water.

The contents blending unit 41 blends the contents from beverage ingredients. Beverage ingredients include sweeteners, fruit juices, plant extracts, dairy products, flavorings, acidity adjusters, vitamins, etc. The contents may also be prepared by mixing one or more of the above beverage ingredients with drinking water in a predetermined ratio. The contents may be beverages such as soda, cola, and other carbonated drinks; beer and other alcoholic beverages; tea; functional beverages; juices; coffee; milk; and milk-based beverages. The contents may also be food seasonings such as soy sauce. Alternatively, the contents may be water, purified water, deionized water, purified water, ultrapure water, or non-drinking liquids.

The contents mixing unit 41 is connected to the first tank 42 via the contents supply system piping 45a. The contents from the contents mixing unit 41 are supplied to this first tank 42.

The first tank 42 is connected to the contents sterilization device 40 via the contents supply piping 45b. A pump 46 is provided in the contents supply piping 45b to supply the contents from the first tank 42 to the contents sterilization device 40. The first tank 42 is connected to a processing fluid inlet 47 into which the aforementioned processing fluid is introduced.

The contents sterilization device 40 sterilizes the contents of a beverage, for example. The contents sterilization device 40 includes a heat exchange unit 50 and a heating unit 52. The heat exchange unit 50 includes heat exchangers 51a to 51c. The heating unit 52 is connected to the heat exchange unit 50. The contents sterilization device 40 further includes a holding tube 53 connected to the heat exchange unit 50 and the heating unit 52.

In this case, the heat exchange unit 50 includes multiple (three in Figure 2) heat exchangers 51a to 51c. That is, the heat exchange unit 50 includes a first heat exchanger 51a, a second heat exchanger 51b, and a third heat exchanger 51c. Within the heat exchange unit 50, the heat exchangers 51a to 51c are connected in series. While the heat exchangers 51a to 51c are shell-and-tube heat exchangers, they are not limited to this type; plate heat exchangers may also be used. Note that the heat exchange unit 50 only needs to include at least one heat exchanger.

The heat exchange unit 50 has a first inlet 50a, a first outlet 50b, a second inlet 50c, and a second outlet 50d. The first inlet 50a is connected to the contents supply system piping 45b. During filling, contents supplied from the contents supply system piping 45b flow into the first inlet 50a. The contents flowing in from the first inlet 50a pass through each heat exchanger 51a to 51c and are sent to the first outlet 50b. During this time, heat exchange takes place inside each heat exchanger 51a to 51c, and the contents flow out from the first outlet 50b. The contents flowing out from the first outlet 50b are sent to the heating unit 52.

The second inlet 50c is connected to the heating section 52. That is, the first outlet 50b and the second inlet 50c are connected via the heating section 52. During filling, the contents sent from the heating section 52 flow into the second inlet 50c. The contents flowing in from the second inlet 50c pass through the heat exchangers 51c to 51a and are sent to the second outlet 50d. The contents flowing in from the second inlet 50c undergo heat exchange within the heat exchangers 51c to 51a and then flow out from the second outlet 50d. The second outlet 50d is connected to the contents supply system piping 45c. The contents flowing out from the second outlet 50d are sent to the temperature control section 43 via the contents supply system piping 45c.

Each heat exchanger 51a to 51c has a tube-side inlet 54a, a tube-side outlet 54b, a shell-side inlet 54c, and a shell-side outlet 54d. The tube-side inlet 54a is located at one end of each heat exchanger 51a to 51c in the longitudinal direction. The tube-side outlet 54b is located at the other end of each heat exchanger 51a to 51c in the longitudinal direction. In each heat exchanger 51a to 51c, the tube-side inlet 54a and the tube-side outlet 54b are positioned opposite each other in the longitudinal direction of each heat exchanger 51a to 51c. The shell-side inlet 54c is located in the shell near the other end of each heat exchanger 51a to 51c in the longitudinal direction. The shell-side outlet 54d is located in the shell near one end of each heat exchanger 51a to 51c in the longitudinal direction. In each heat exchanger 51a to 51c, the shell-side inlet 54c and shell-side outlet 54d are oriented perpendicular to the longitudinal direction of the heat exchangers 51a to 51c, but this is not limited to this orientation. The shell-side inlet 54c and shell-side outlet 54d may be oriented obliquely to the longitudinal direction of the heat exchangers 51a to 51c.

During the filling process, the contents supplied from the contents supply system piping 45b flow into the pipe-side inlet 54a. The pipe-side inlet 54a communicates with the pipe-side outlet 54b inside each heat exchanger 51a-51c. The contents flowing in from the pipe-side inlet 54a undergo heat exchange inside each heat exchanger 51a-51c and flow out from the pipe-side outlet 54b. The contents flowing out from the pipe-side outlet 54b are sent to the heating section 52. Also during the filling process, the contents supplied from the heating section 52 flow into the shell-side inlet 54c. The shell-side inlet 54c communicates with the shell-side outlet 54d inside each heat exchanger 51a-51c. The contents flowing in from the shell-side inlet 54c undergo heat exchange inside each heat exchanger 51a-51c and flow out from the shell-side outlet 54d.

Within the contents sterilization device 40, the contents supply system piping 45b is connected to the pipe-side inlet 54a of the first heat exchanger 51a. The pipe-side outlet 54b of the first heat exchanger 51a and the pipe-side inlet 54a of the second heat exchanger 51b are connected by connecting piping 55a. The pipe-side outlet 54b of the second heat exchanger 51b and the pipe-side inlet 54a of the third heat exchanger 51c are connected by connecting piping 55b. Furthermore, the circulation system piping 56 is connected to the pipe-side outlet 54b of the third heat exchanger 51c. The circulation system piping 56 is connected to the shell-side inlet 54c of the third heat exchanger 51c. The circulation system piping 56 is provided with the heating section 52 and the holding tube 53 described above. Furthermore, the shell-side outlet 54d of the third heat exchanger 51c and the shell-side inlet 54c of the second heat exchanger 51b are connected by a connecting pipe 55c. Additionally, the shell-side outlet 54d of the second heat exchanger 51b and the shell-side inlet 54c of the first heat exchanger 51a are connected by a connecting pipe 55d.

The heating unit 52 heats the contents flowing through the circulation system piping 56 to the final sterilization temperature. The heating unit 52 may also be a heater. For example, a heat exchanger may be used as this heater.

The holding tube 53 is located downstream of the heating section 52 in the circulation system piping 56. The holding tube 53 includes coiled curved tubes, straight tubes, or spiral tubes, and undergoes heat treatment or sterilization while flowing through it. The contents are designed to pass through the holding tube 53 for a predetermined residence time or longer. By maintaining a constant residence time (holding time) and sterilization temperature within the holding tube 53, the sterility of the fluid, such as the contents or processing fluid, can be ensured.

The contents sterilization device 40 is connected to the temperature control unit 43 via the contents supply system piping 45c. The temperature control unit 43 is a device for adjusting the temperature of the contents sterilized in the contents sterilization device 40 to the filling temperature. The temperature control unit 43 may also be a cooling device that lowers the temperature of the contents. The temperature control unit 43 may also be a heat exchanger. The temperature control unit 43 has a third inlet 43a, a third outlet 43b, a fourth inlet 43c, and a fourth outlet 43d. The contents from the contents supply system piping 45c flow into the third inlet 43a. The contents that flowed in from the third inlet 43a flow out of the third outlet 43b. A temperature control liquid such as cooling water flows into the fourth inlet 43c. The temperature control liquid that flowed in from the fourth inlet 43c flows out of the fourth outlet 43d. In the temperature control unit 43, heat exchange takes place between the contents flowing in from the third inlet 43a and the temperature-controlled liquid flowing in from the fourth inlet 43c, thereby adjusting the temperature of the contents flowing out from the third outlet 43b. Note that if the allowable temperature range of the contents to be filled by the filling device 20 is wide (for example, 30°C ± 20°C), the temperature control unit 43 may not be necessary. In this case, the flow path of the contents from the fifth branch 62e may be switched to the circulation piping 63c side. Afterward, the temperature of the contents may be adjusted while circulating the contents until the temperature of the contents at the second outlet 50d reaches the allowable temperature range of the manufacturing temperature. Furthermore, if the filling temperature of the contents is medium to high (for example, 50°C to 100°C), the contents may be directly supplied to the filling device 20 from an intermediate point in the heat exchanger (for example, the third heat exchanger 51c or the second heat exchanger 51b).

The temperature control unit 43 is connected to the second tank 44 via the contents supply system piping 45d. The contents from the contents supply system piping 45d are stored in the second tank 44. The second tank 44 temporarily stores the contents whose temperature has been controlled by the temperature control unit 43. The second tank 44 may also be called a filling head tank or a buffer tank. The second tank 44 may be located in the upper part of the filling device 20.

In the filling device 20, the contents stored in the second tank 44 are filled into empty bottles 90. The filling device 20 has a rotating wheel 21. Multiple bottles 90 are rotated (revolved) by this wheel 21 as the contents are filled into the bottles 90. Multiple filling nozzles 22 are arranged along the outer circumference of the rotating wheel 21. Each filling nozzle 22 is fitted with one bottle 90, and the contents are injected into the bottles 90 from the filling nozzle 22. A contents supply line 23 is connected to the filling nozzles 22. One end of the contents supply line 23 is connected to the second tank 44, which is filled with contents, and the other end communicates with the inside of the bottles 90. The contents supplied from the second tank 44 pass through the contents supply line 23 and are injected into the bottles 90.

The rotating wheel 21 and filling nozzle 22 are covered by a chamber 24, for example, made of stainless steel plate. A rotary joint 25 is attached to the top of the chamber 24. This rotary joint 25 seals the rotating parts (rotating wheel 21 and filling nozzle 22, etc.) and the non-rotating parts (chamber 24, etc.) in a sterile manner.

Furthermore, a first branch section 62a and a second branch section 62b are provided in the middle of the contents supply system piping 45b. The first circulation pipe 63a is connected to the first branch section 62a. The first circulation pipe 63a is connected to the third circulation pipe 63c (described later) at the third branch section 62c. The second circulation pipe 63b is connected to the second branch section 62b. The second circulation pipe 63b is connected to the third circulation pipe 63c (described later) at the fourth branch section 62d. Additionally, a fifth branch section 62e is provided in the middle of the contents supply system piping 45d. The third circulation pipe 63c is connected to the fifth branch section 62e. The third circulation pipe 63c is connected to the first tank 42.

A fourth heat exchanger 66 (an additional heat exchanger) is installed in the middle of the third circulation pipe 63c. The fourth heat exchanger 66 performs heat exchange between the processing fluid flowing through the contents supply system pipe 45b and the processing fluid flowing through the third circulation pipe 63c. During the cleaning process (CIP process), the fourth heat exchanger 66 utilizes the temperature of the processing fluid discharged from the contents sterilization device 40 to raise the temperature of the processing fluid flowing into the contents sterilization device 40.

The fourth heat exchanger 66 has a fifth inlet 66a, a fifth outlet 66b, a sixth inlet 66c, and a sixth outlet 66d. Contents from the contents supply system piping 45b flow into the fifth inlet 66a. Alternatively, the fifth inlet 66a allows the processed fluid to flow in or out. Contents that flowed in from the fifth inlet 66a flow out from the fifth outlet 66b. Alternatively, the fifth outlet 66b allows the processed fluid to flow out or in. Processed fluid passing through the third circulation piping 63c flows into or out of the sixth inlet 66c. Processed fluid passing through the sixth inlet 66c flows out or in through the sixth outlet 66d. In the fourth heat exchanger 66, heat exchange takes place between the processed fluid flowing in from the fifth inlet 66a and the processed fluid flowing in from the sixth inlet 66c, and the temperature of the processed fluid flowing out from the fifth outlet 66b is adjusted. Alternatively, in the fourth heat exchanger 66, heat exchange takes place between the processed fluid flowing in from the sixth outlet 66d and the processed fluid flowing in from the fifth outlet 66b, thereby adjusting the temperature of the processed fluid flowing out from the sixth inlet 66c.

A first valve 64a is provided in the contents supply piping 45b between the first branch 62a and the second branch 62b. A second valve 64b is provided in the first circulation piping 63a. A third valve 64c is provided in the second circulation piping 63b. A fourth valve 64d is provided in the contents supply piping 45d between the fifth branch 62e and the filling device 20. Furthermore, a fifth valve 64e is provided in the third circulation piping 63c between the third branch 62c and the fourth branch 62d. The opening and closing of these first valves 64a to the fifth valves 64e are controlled by the control unit 60.

A back pressure valve 48 is provided in the middle of the contents supply piping 45d, between the temperature control section 43 and the fifth branch section 62e. The back pressure valve 48 allows for adjustment of the flow rate and internal pressure of the contents supply piping 45d. This ensures that, in forward flow, the fluid pressure of the processed fluid passing after the holding tube 53 in the heat exchange unit 50 is maintained at a higher level than the fluid pressure of the processed fluid passing before the holding tube 53. Specifically, in forward flow, the pressure of the processed fluid at the shell-side outlet 54d in each of the heat exchangers 51c to 51a is made higher than the pressure of the processed fluid at the pipe-side outlet 54b. When back pressure is applied when the maximum temperature of the processed fluid passing through the contents sterilization device 40 is 100°C or higher, the pressure in the piping of the contents sterilization device 40 increases. To control the fluid pressure of the processed fluid in this state to maintain the above pressure balance, it is advisable to install one or more booster pumps (not shown) between the pump 46 and the holding tube 53. More preferably, the booster pump is installed between the heating unit 52 and the third heat exchanger 51c, or between the third heat exchanger 51c and the second heat exchanger 51b. That is, by installing one or more back pressure valves 48 and booster pumps, the above-mentioned pressure balance can be achieved while maintaining the flow rate necessary for cleaning and the temperature necessary for sterilization.

For convenience, the thermometer, concentration meter, pressure gauge, and flow meter are omitted from the diagrams. These thermometers, concentration meters, pressure gauges, and flow meters are installed at various locations and may be used for control by the control unit 60.

Next, the internal structure of each heat exchanger 51a to 51c will be described with reference to Figure 3. Figure 3 is a cross-sectional view of each heat exchanger 51a to 51c. Note that each heat exchanger 51a to 51c may have the same structure.

As shown in Figure 3, each heat exchanger 51a to 51c has a shell 71, a pair of tube sheets 72a and 72b provided at both longitudinal ends of the shell 71, and a plurality of tubes 73 extending into the shell 71.

The shell 71 is cylindrical or tubular in shape. Inside the shell 71, a space S is formed around the multiple tubes 73 through which a fluid, such as the contents, passes. The body of the shell 71 is provided with a body-side inlet 54c and a body-side outlet 54d. The body-side inlet 54c is located at the longitudinal end of the shell 71, near the tube-side outlet 54b. The body-side outlet 54d is also located at the longitudinal end of the shell 71, near the tube-side inlet 54a.

The pair of tube sheets 72a and 72b are each disc-shaped and close both longitudinal ends of the shell 71. Openings are formed in both tube sheets 72a and 72b, and the ends of the tubes 73 are fixed to each opening. A tube-side inlet 54a is formed on one tube sheet 72a, and a tube-side outlet 54b is formed on the other tube sheet 72b.

Multiple tubes 73 each extend from one tube sheet 72a to the other tube sheet 72b. The multiple tubes 73 are arranged radially apart from each other. Fluid, such as contents, flowing in from the tube-side inlet 54a passes through the multiple tubes 73 and flows out from the tube-side outlet 54b. Meanwhile, fluid, such as contents, flowing in from the shell-side inlet 54c passes through the space S within the shell 71 and flows out from the shell-side outlet 54d. Within each heat exchanger 51a to 51c, the space S and the tubes 73 do not communicate with each other. Heat exchange occurs within each heat exchanger 51a to 51c between the fluid passing through the tubes 73 and the fluid passing through the space S. As a result, the temperature of the fluid passing through the tubes 73 rises (falls), and the temperature of the fluid passing through the space S falls (rises).

(Content filling method)
Next, a method for filling contents using the contents filling system 10 described above will be explained. In the following, the method for filling contents under normal circumstances, that is, a method for filling contents into bottle 90 to produce product bottle 95, will be described.

First, the preform supply device 37 sequentially supplies multiple preforms 91 to the preform receiving section 34 of the preform transport section 31 via the preform supply conveyor 37a (preform supply process). At this time, the preforms 91 are sterilized by spraying them with hydrogen peroxide gas or mist in the preform sterilization device 34a, and then dried with hot air.

Next, the preform 91 is sent to the preform heating unit 35, where it is heated by the heater 35a to, for example, a temperature between 90°C and 130°C. Then, the preform 91, heated by the preform heating unit 35, is sent to the preform transfer unit 36. Finally, the preform 91 is sent from the preform transfer unit 36 to the blow molding unit 32.

Next, the preform 91, which has been sent to the blow molding section 32, is blow-molded using a mold (not shown) to form the bottle 90 (bottle molding process). The blow-molded bottle 90 is then sent to the bottle transport section 33.

Next, in the container sterilization apparatus 11, the bottle 90 is sterilized using a hydrogen peroxide aqueous solution, which is a disinfectant (container sterilization step). At this time, the disinfectant may be a gas or mist obtained by vaporizing the hydrogen peroxide aqueous solution above its boiling point. The hydrogen peroxide gas or mist adheres to the inner and outer surfaces of the bottle 90, sterilizing both the inner and outer surfaces of the bottle 90.

Next, bottle 90 is sent to the air rinsing device 14. In the air rinsing device 14, sterile heated air or sterile room-temperature air is supplied to bottle 90, activating the hydrogen peroxide and removing foreign matter and hydrogen peroxide from bottle 90 (air rinsing process). In the air rinsing process, if necessary, a low-concentration hydrogen peroxide condensation mist may be mixed with the sterile heated air or sterile room-temperature air. In this case, the hydrogen peroxide is gasified by the sterile air. Then, in the air rinsing process, the gasified hydrogen peroxide may be supplied to bottle 90.

Next, bottle 90 is transported to filling device 20.

During this time, the contents are prepared from the beverage raw materials in the contents mixing unit 41 (contents preparation process). These contents are sent to the first tank 42 via the contents supply piping 45a and stored there. Subsequently, the contents are sent by the pump 46 to the contents sterilization device 40 via the contents supply piping 45b and the fourth heat exchanger 66. In the contents sterilization device 40, the contents flow in from the first inlet 50a of the heat exchange unit 50, undergo heat exchange in each heat exchanger 51a to 51c, and after the temperature rises, flow out from the first outlet 50b. The contents that have flowed out from the first outlet 50b are further heated in the heating unit 52 and sent to the holding tube 53. The contents require a certain amount of time (residence time) or more to pass through the holding tube 53, during which time they maintain a temperature above a predetermined level. Subsequently, the contents flow in through the second inlet 50c of the heat exchange unit 50, undergo heat exchange in each heat exchanger 51a to 51c, and after a temperature drop, flow out through the second outlet 50d. In this way, sterilization of the contents is completed. Note that during filling, the first valve 64a and the fourth valve 64d are open, and the second valve 64b, the third valve 64c, and the fifth valve 64e are closed. Also, the first circulation pipe 63a, the second circulation pipe 63b, and the third circulation pipe 63c are not used.

The sterilized contents are sent to the temperature control unit 43 via the contents supply piping 45c. The temperature control unit 43 performs the final temperature adjustment of the contents. Specifically, the temperature of the contents is lowered to the filling temperature of the filling device 20. The filling temperature may be, for example, between 1°C and 40°C, preferably between 5°C and 30°C. The contents from the temperature control unit 43 are sent to the second tank 44 for storage.

In the filling device 20, the bottle 90 rotates (revolves) while the contents are filled into the bottle 90 from its opening. In the filling device 20, the contents sent from the second tank 44 are filled into the sterilized bottle 90 at a filling temperature of 1°C to 40°C, preferably 5°C to 30°C.

Subsequently, the bottles 90, filled with their contents by the filling device 20, are transported to the capping device 16 by the transport wheels 12.

Meanwhile, the cap 92 is sterilized beforehand by the cap sterilization device 18 (cap sterilization process). During this process, the cap 92 is first brought into the cap sterilization device 18 from outside the contents filling system 10. Subsequently, in the cap sterilization device 18, the cap 92 is sterilized on its inner and outer surfaces by being sprayed with hydrogen peroxide gas or mist, then dried with hot air, and sent to the cap mounting device 16.

Next, in the capping device 16, a sterilized cap 92 is attached to the mouth of the bottle 90 that has been transported from the filling device 20, thereby sealing the bottle 90 and obtaining the product bottle 95 (capping process).

Subsequently, the product bottle 95 is transported from the cap-attaching device 16 to the product bottle discharge section 19 and discharged to the outside of the contents filling system 10 (bottle discharge process). Then, the product bottle 95 is transported to a packaging line (not shown) and packaged.

Furthermore, the production (conveying) speed of the bottles 90 in the contents filling system 10 is preferably 100 bpm or more and 1500 bpm or less. Here, bpm (bottles per minute) refers to the conveying speed of bottles 90 per minute.

(Washing and sterilization methods)
Next, the operation of the contents filling system 10 when cleaning (CIP) and sterilization (SIP) processes are performed, for example, periodically or when switching between types of beverages, will be explained. The control of the cleaning process described below is performed by the control unit 60.

In the following, the processing fluid may be any of the following: water rinse solution, alkaline cleaning solution, acidic cleaning solution, heated steam, or hot water. The cleaning process (CIP process) includes water rinsing, alkaline cleaning, and acidic cleaning. Of these, the water rinsing process is a process of rinsing the flow path in the contents filling system 10 with water rinsing solution. The alkaline cleaning process is a process of flowing an alkaline cleaning solution, for example, by adding an alkaline agent such as caustic soda to water, through the flow path in the contents filling system 10. The acidic cleaning process is a process of flowing an acidic cleaning solution, for example, by adding an acidic agent to water, through the flow path in the contents filling system 10. The sterilization process (SIP process) is a process of performing high-temperature sterilization by flowing heated steam or hot water through the flow path through which the contents will pass before the contents filling operation begins. In this embodiment, the sterilization process (SIP process) may be performed after the cleaning process (CIP process). Furthermore, a combined washing and sterilization treatment (CSIP treatment) may be performed without a separate sterilization treatment (SIP treatment).

(Forward flow treatment)
First, let's explain the forward flow process. In the forward flow process, the processed fluid either passes through in the forward flow direction (the same direction as the flow direction when the contents are filled) or is circulated in the forward flow direction.

In this case, the first valve 64a and the fifth valve 64e are opened in advance, and the second valve 64b, the third valve 64c, and the fourth valve 64d are closed. In the forward flow treatment, the third circulation pipe 63c is used, and the first circulation pipe 63a and the second circulation pipe 63b are not used.

Next, the processed fluid is sent from the processed fluid input section 47 to the piping system formed by the contents supply system piping 45a to 45d and the third circulation piping 63c. As this processed fluid passes through or circulates, the piping system, the first tank 42, the contents sterilization device 40, and the temperature control section 43 are each purified.

As shown in Figure 4, for example, the treatment fluid is supplied to the first tank 42, and as this treatment fluid passes through or circulates, the piping system, the first tank 42, the contents sterilization device 40, and the temperature control unit 43 are purified. In Figure 4, the flow path of the treatment fluid is indicated by a thick line.

During this time, the processing fluid is supplied to the contents sterilization device 40 via the fourth heat exchanger 66 by a pump 46 located in the contents supply system piping 45b. The processing fluid exchanges heat with the high-temperature processing fluid flowing in from the sixth inlet 66c within the fourth heat exchanger 66, causing its temperature to rise. This processing fluid then flows into the contents sterilization device 40 from the first inlet 50a of the heat exchange unit 50. The processing fluid flowing in from the first inlet 50a passes sequentially through the first heat exchanger 51a, the second heat exchanger 51b, and the third heat exchanger 51c. Within the first heat exchanger 51a, the second heat exchanger 51b, and the third heat exchanger 51c, the processing fluid exchanges heat with the high-temperature processing fluid flowing in from the second inlet 50c, causing its temperature to rise. The heated processing fluid then flows out from the first outlet 50b.

The heated processing fluid flows through the circulation system piping 56 and is further heated in the heating section 52. This heated processing fluid then reaches the holding tube 53. The processing fluid requires a certain amount of time (residence time) or more to pass through the holding tube 53, during which time it maintains a temperature above a predetermined level. Afterward, the processing fluid flows from the circulation system piping 56 into the second inlet 50c of the heat exchange unit 50.

The processed fluid flowing in from the second inlet 50c passes sequentially through the third heat exchanger 51c, the second heat exchanger 51b, and the first heat exchanger 51a. Within the third heat exchanger 51c, the second heat exchanger 51b, and the first heat exchanger 51a, the processed fluid exchanges heat with the low-temperature processed fluid flowing in from the first inlet 50a, causing its temperature to decrease. The cooled processed fluid then flows out from the second outlet 50d.

The processed fluid flowing out from the second outlet 50d of the heat exchange unit 50 reaches the temperature control unit 43 via the contents supply piping 45c. Next, the processed fluid reaches the third circulation piping 63c via the contents supply piping 45d and the fifth branch section 62e in sequence. In the third circulation piping 63c, the processed fluid passes through the fourth heat exchanger 66. At this point, the processed fluid exchanges heat with the low-temperature processed fluid flowing in from the fifth inlet 66a within the fourth heat exchanger 66, causing its temperature to decrease.

When a rinse solution is used as the processing fluid (rinse treatment), the processing fluid is discharged to the outside through the third circulation pipe 63c. When an alkaline cleaning solution, an acidic cleaning solution, or hot water is used as the processing fluid (alkaline cleaning treatment, acidic cleaning treatment, SIP treatment), the processing fluid circulates. Therefore, the processing fluid reaches the first tank 42 from the third circulation pipe 63c. Afterward, the processing fluid is again sent from the first tank 42 to the heat exchange unit 50 by the pump 46. In this way, the alkaline cleaning solution, acidic cleaning solution, or hot water circulates for a predetermined time through the piping system formed by the contents supply system pipes 45a to 45d and the third circulation pipe 63c, the first tank 42, the contents sterilization device 40, and the temperature control unit 43. After circulating for the predetermined time, the alkaline cleaning solution, acidic cleaning solution, or hot water is discharged to the outside.

If the processing fluid is an alkaline or acidic cleaning solution, the processing fluid is heated by the heat exchange unit 50. The heated processing fluid is supplied to the piping system, the first tank 42, the contents sterilization device 40, and the temperature control unit 43, respectively. When this circulation is performed for, for example, 5 minutes to 60 minutes, the piping system, the first tank 42, the contents sterilization device 40, and the temperature control unit 43 are properly purified. At the same time, the piping system, the first tank 42, the contents sterilization device 40, and the temperature control unit 43 are sterilized, and SIP processing is performed simultaneously without the need for separate SIP processing (CIP processing). In this way, by cleaning the various components of the contents filling system 10 with CIP processing and simultaneously performing sterilization processing, the time required for SIP processing can be shortened or SIP processing itself can be eliminated. This shortens the product changeover time of the contents filling system 10 and improves production capacity. Furthermore, during the SIP process, the processing fluid flowing through the first tank 42, pump 46, and fourth heat exchanger 66 is at a lower temperature than the processing fluid flowing through the contents sterilization device 40 and temperature control unit 43. Therefore, the first tank 42, pump 46, and fourth heat exchanger 66 may be excluded from the SIP process.

(Backflow treatment)
Next, we will explain the backflow treatment. In backflow treatment, the treatment fluid either passes in the reverse direction (opposite to the flow direction during content filling) or is circulated in the reverse direction.

In this case, the second valve 64b and the third valve 64c are opened in advance, and the first valve 64a, the fourth valve 64d, and the fifth valve 64e are closed. For backflow treatment, the first circulation pipe 63a, the second circulation pipe 63b, and the third circulation pipe 63c are used.

At this time, as shown in Figure 5, the processed fluid is sent from the processed fluid input section 47 to the piping system formed by the contents supply pipes 45a to 45d and the circulation pipes 63a to 63c. During the backflow treatment, the processed fluid circulates in the opposite direction to the forward flow treatment. This purifies the piping system formed by the contents supply pipes 45a to 45d and the circulation pipes 63a to 63c, the temperature control section 43, the contents sterilization device 40, and the first tank 42. In Figure 5, the flow path of the processed fluid is indicated by a thick line.

During this time, the processing fluid is sent to the first circulation pipe 63a via the first branch section 62a by a pump 46 located in the contents supply system piping 45b. Subsequently, the processing fluid flows into the temperature control section 43 sequentially through the third branch section 62c, the third circulation pipe 63c, the fifth branch section 62e, and the contents supply system piping 45d. During this time, the processing fluid passes through the fourth heat exchanger 66 located in the third circulation pipe 63c. Within the fourth heat exchanger 66, the processing fluid exchanges heat with the high-temperature processing fluid flowing in from the fifth outlet 66b, causing its temperature to rise.

Next, the processing fluid flows into the heat exchange unit 50 through the contents supply system piping 45c from the second outlet 50d. The processing fluid flowing in from the second outlet 50d passes sequentially through the first heat exchanger 51a, the second heat exchanger 51b, and the third heat exchanger 51c. Within the first heat exchanger 51a, the second heat exchanger 51b, and the third heat exchanger 51c, the processing fluid exchanges heat with the high-temperature processing fluid flowing in from the first outlet 50b, causing its temperature to rise. The heated processing fluid then flows out from the second inlet 50c.

The heated processing fluid reaches the holding tube 53 via the circulation piping 56. The processing fluid requires a certain amount of time (residence time) or more to pass through the holding tube 53, during which time it maintains a temperature above a predetermined level. Subsequently, the processing fluid is further heated in the heating section 52. Afterward, the processing fluid flows from the circulation piping 56 into the first outlet 50b of the heat exchange unit 50.

The processed fluid flowing in from the first outlet 50b passes sequentially through the third heat exchanger 51c, the second heat exchanger 51b, and the first heat exchanger 51a. Within the third heat exchanger 51c, the second heat exchanger 51b, and the first heat exchanger 51a, the processed fluid exchanges heat with the lower-temperature processed fluid flowing in from the second outlet 50d, causing its temperature to decrease. The cooled processed fluid then flows out from the first inlet 50a.

The processed fluid flowing out from the first inlet 50a of the heat exchange unit 50 reaches the second circulation pipe 63b via the contents supply system piping 45b and the second branch section 62b. During this time, the processed fluid passes through the fourth heat exchanger 66 located in the contents supply system piping 45b. Within the fourth heat exchanger 66, the processed fluid exchanges heat with the low-temperature processed fluid flowing in from the sixth outlet 66d, causing its temperature to decrease.

When a rinse solution is used as the processing fluid (rinse treatment), the processing fluid is discharged to the outside through the second circulation pipe 63b. When an alkaline cleaning solution, acidic cleaning solution, or hot water is used as the processing fluid (alkaline cleaning treatment, acidic cleaning treatment, SIP treatment), the processing fluid circulates. Therefore, the processing fluid reaches the first tank 42 sequentially via the second circulation pipe 63b and the fourth branch section 62d. Afterward, the processing fluid is sent again from the first tank 42 to the temperature control unit 43 by the pump 46. In this way, the alkaline cleaning solution, acidic cleaning solution, or hot water circulates and cleans the piping system formed by the contents supply pipes 45a to 45d and the circulation pipes 63a to 63c, the temperature control unit 43, the contents sterilization device 40, and the first tank 42 for a predetermined time. After circulating for the predetermined time, the alkaline cleaning solution, acidic cleaning solution, or hot water is discharged to the outside.

In the backflow treatment process, the piping system, the first tank 42, the contents sterilization device 40, and the temperature control unit 43 may each be properly purified and sterilized (CSIP treatment).

In the above procedure, forward flow treatment is performed followed by reverse flow treatment. However, it is not limited to this; reverse flow treatment may be performed first, followed by forward flow treatment. This allows for a reduction in cleaning time depending on the nature of the fouling adhering to the heat exchangers 51a-51c, contributing to energy savings. Alternatively, forward flow treatment may be performed, followed by reverse flow treatment, and then forward flow treatment again. This allows for effective cleaning of poorly cleaned areas within the heat exchangers 51a-51c, resulting in reduced cleaning time, reduced steam consumption, reduced carbon dioxide emissions, reduced cleaning solution, water conservation, and reduced wastewater.

Furthermore, when performing the forward flow treatment described above, it was found that the treatment fluid did not sufficiently reach some parts of the heat exchangers 51a to 51c, resulting in insufficient cleaning in certain areas. In particular, as shown in Figure 3, the treatment fluid flowing into the space S from the shell-side inlet 54c flows toward the shell-side outlet 54d and one of the tube sheets 72a (solid arrow F1 in Figure 3). Generally, in heat exchangers 51a to 51c, the shell-side inlet 54c is located at a position slightly separated from the other tube sheet 72b. Therefore, the treatment fluid does not sufficiently enter the area between the other tube sheet 72b and the shell-side inlet 54c (the area indicated by the symbol R in Figure 3), potentially resulting in uneven cleaning and insufficient cleaning of this area R. However, the treatment fluid flows into the area on the one tube sheet 72a side, ensuring sufficient cleaning.

In contrast, according to this embodiment, as described above, in addition to forward flow treatment, backflow treatment is performed. In backflow treatment, the treatment fluid is flowed in the opposite direction to the forward flow treatment. In this case, as shown in Figure 3, the treatment fluid that flows into the space S from the shell-side outlet 54d flows toward the shell-side inlet 54c and the other tube sheet 72b (dashed arrow F2 in Figure 3). Therefore, the treatment fluid flows sufficiently into the region R inside the shell 71 between the other tube sheet 72b and the shell-side inlet 54c, and this region R can be thoroughly cleaned.

Furthermore, the contents mixing unit 41, the filling device 20, and the second tank 44 are also separately cleaned and sterilized using an alkaline cleaning solution and an acidic cleaning solution.

After the washing and sterilization processes are completed, the contents are stored in the first tank 42. Subsequently, the contents pass through the contents sterilization device 40 to the filling device 20, and the manufacturing process of filling the contents into the bottles 90 begins.

(Processing patterns for cleaning and sterilization)
Next, we will explain examples of the treatment patterns for the CIP (cleaning), SIP (sterilization), and CSIP (cleaning and sterilization) treatments described above. In CIP, SIP, and CSIP treatments, some or all of the following are performed: rinsing with a water rinse solution, alkaline cleaning with an alkaline cleaning solution, acidic cleaning with an acidic cleaning solution, or sterilization with hot water.

As shown in Figures 6(a)-(e), for example, the treatment may be carried out in the order of CIP treatment and SIP treatment after the content filling process (manufacturing process), and then the next content filling process (manufacturing process) may be carried out. Note that the order of alkaline and acidic cleaning treatments shown in Figures 6(a)-(e) is just an example, and may be changed as appropriate according to the cleaning properties of the target stains.

(Pattern 1)
As shown in Figure 6(a), in the CIP treatment, (1) water rinsing, (2) alkaline cleaning, (3) water rinsing, (4) acidic cleaning, (5) water rinsing may be performed, followed by (6) SIP treatment with hot water. Of these, (1) water rinsing, (2) alkaline cleaning, (3) water rinsing, and (6) SIP treatment correspond to forward flow treatment. (4) acidic cleaning and (5) water rinsing correspond to backflow treatment.

(Pattern 2)
As shown in Figure 6(b), in the CIP treatment, (1) water rinsing, (2) alkaline cleaning, (3) water rinsing, (4) acidic cleaning, (5) water rinsing may be performed, followed by (6) SIP treatment with hot water. Of these, (1) water rinsing, (4) acidic cleaning, (5) water rinsing, and (6) SIP treatment correspond to forward flow treatment. (2) alkaline cleaning and (3) water rinsing correspond to backflow treatment.

(Pattern 3)
As shown in Figure 6(c), in the CIP treatment, (1) water rinsing, (2) acidic cleaning, (3) water rinsing, (4) alkaline cleaning, and (5) water rinsing may be performed, followed by (6) SIP treatment with hot water. Of these, (1) water rinsing, (3) water rinsing, (5) water rinsing, and (6) SIP treatment correspond to forward flow treatment. (2) acidic cleaning and (4) alkaline cleaning correspond to backflow treatment.

(Pattern 4)
As shown in Figure 6(d), in the CIP treatment, (1) water rinsing, (2) first acidic washing, (3) second acidic washing, (4) water rinsing, (5) first alkaline washing, (6) second alkaline washing may be performed, followed by (7) SIP treatment with hot water. Of these, (1) water rinsing, (2) first acidic washing, (5) first alkaline washing, and (7) SIP treatment correspond to forward flow treatment. (3) second acidic washing, (4) water rinsing, and (6) second alkaline washing correspond to backflow treatment.

(Pattern 5)
As shown in Figure 6(e), in the CIP treatment, (1) water rinsing, (2) first acidic washing, (3) second acidic washing, (4) first alkaline washing, (5) second alkaline washing may be performed, followed by (6) SIP treatment with hot water. Of these, (1) water rinsing, (2) first acidic washing, (4) first alkaline washing, and (6) SIP treatment correspond to forward flow treatment. (3) second acidic washing and (5) second alkaline washing correspond to backflow treatment.

As shown in Figures 7(a)-(c), for example, the treatment may be carried out in the order of CIP treatment and CSIP treatment after the content filling process (manufacturing process), and then the next content filling process (manufacturing process) may be carried out. Note that the order of acidic and alkaline cleaning treatments shown in Figures 7(a)-(c) is just an example, and may be changed as appropriate according to the cleaning properties of the target contaminants.

(Pattern 6)
As shown in Figure 7(a), in the CIP treatment, (1) water rinsing treatment, (2) acidic cleaning treatment, and (3) water rinsing treatment may be performed, and then in the CSIP treatment, (4) alkaline cleaning treatment and (5) water rinsing treatment may be performed. Of these, (1) water rinsing treatment, (4) alkaline cleaning treatment, and (5) water rinsing treatment correspond to forward flow treatment. (2) acidic cleaning treatment and (3) water rinsing treatment correspond to backflow treatment.

(Pattern 7)
As shown in Figure 7(b), in the CIP treatment, (1) water rinsing, (2) first acidic washing, (3) second acidic washing, and (4) first alkaline washing may be performed, and then in the CSIP treatment, (5) second alkaline washing and (6) water rinsing may be performed. Of these, (1) water rinsing, (2) first acidic washing, (5) second alkaline washing, and (6) water rinsing correspond to forward flow treatment. (3) second acidic washing and (4) first alkaline washing correspond to backflow treatment.

(Pattern 8)
As shown in Figure 7(c), in the CIP treatment, (1) water rinsing, (2) first acidic washing, (3) second acidic washing, (4) first alkaline washing, and (5) second alkaline washing may be performed, and then in the CSIP treatment, (6) water rinsing may be performed. Of these, (1) water rinsing, (2) first acidic washing, (5) second alkaline washing, and (6) water rinsing correspond to forward flow treatment. (3) second acidic washing and (4) first alkaline washing correspond to backflow treatment.

As illustrated in patterns 1 to 8 above, the final step of the washing and sterilization methods is preferably a forward flow treatment step. This allows the process to transition to production while maintaining a sterile state from the heating section 52 to the holding tube 53, and while the fluid pressure of the processing fluid passing through the heat exchangers 51a to 51c after the holding tube 53 remains higher than the fluid pressure of the processing fluid passing before the holding tube 53 (without reversing the safety back pressure).

As illustrated in patterns 5, 7, and 8 above, a rinsing step is not required between the acidic and alkaline cleaning treatments. In this case, the alkaline cleaning treatment may be performed immediately after the acidic cleaning treatment, or vice versa. This shortens the cleaning time, saves water, and contributes to energy conservation. Furthermore, a cleaning effect can sometimes be obtained through a pH attack (a localized and rapid pH change). The pH of the acidic cleaning solution is, for example, between 1 and 3, and the pH of the alkaline cleaning solution is, for example, between 11 and 13. That is, the pH range for the pH attack is, for example, between 8 and 12. The pH range for the pH attack refers to the difference between the pH of the alkaline cleaning solution and the pH of the acidic cleaning solution.

The table below shows the temperature of the processing fluid flowing through each part of the contents filling system 10 during the CIP (cleaning), SIP (sterilization), and CSIP (cleaning and sterilization) processes described above. Specifically, it shows the temperatures at the first tank 42, contents supply piping 45b, first circulation piping 63a, first inlet 50a, first outlet 50b, second inlet 50c, second outlet 50d, contents supply piping 45c, contents supply piping 45d, sixth inlet 66c, sixth outlet 66d, and second circulation piping 63b of the contents filling system 10.

(Method for heating the processing fluid)
Next, we will explain the method for heating the treatment fluid during the cleaning and sterilization treatment (CSIP treatment) described above.

During the cleaning and sterilization process (CSIP process), the processing fluid is sent to the contents sterilization device 40 and heated in the heating section 52 of the contents sterilization device 40. This heated processing fluid then passes through the holding tube 53 and is supplied to the heat exchange unit 50. The processing fluid requires a certain period of time (residence time) or longer to pass through the holding tube 53, during which time it maintains a temperature above a predetermined level.

The degree of sterilization of the processing fluid passing through the holding tube 53 may be controlled by the F value. For example, the temperature at the outlet side of the holding tube 53 may be measured while the processing fluid is flowing through it. In this case, the temperature information at the outlet side is sent to the control unit 60 at regular time intervals. The control unit 60 calculates the F value at that time based on this temperature information. Here, the F value is the heating time required to kill all bacteria when they are heated for a certain period of time. It is represented by the lethal time of bacteria at a reference temperature and is calculated using the following formula.

In the above formula, T is the temperature (°C) measured at the outlet side of the holding tube 53, 10^{(T-Tr)/Z} is the lethality at the sterilization temperature T, Tr is the reference temperature (°C), and Z is the Z value (°C). Also, _t1 (min) is the (minimum) residence time required for the processing fluid to pass through the holding tube 53, and is predetermined as a specific value. Alternatively, t1 (min) may be the value obtained by measuring in real time the time the processing fluid actually passes through the holding tube 53 based on the flow rate of the processing fluid in the holding tube 53 and the volume of the holding tube 53. The F value during washing and sterilization should be set to be equal to or greater than the sterilization conditions for the next type of contents to be manufactured, or to _F03 or higher (Z=10°C).

The control unit 60 monitors the F value calculated based on the temperature at the outlet, and continues the cleaning process if this value remains above a predetermined value. Specifically, the control unit 60 accumulates the value of 10^{(T-Tr)/Z} based on temperature information sent at regular time intervals. The accumulated value from the current time to the immediately preceding _t1 (minute) is then taken as the F value at that time. If this F value remains above a predetermined value, the control unit 60 assumes that the sterility of the processing fluid passing through the holding tube 53 is ensured and continues the cleaning process. On the other hand, if the F value falls below a predetermined value, the control unit 60 may determine that some kind of trouble has occurred and the sterility of the processing fluid can no longer be ensured, and may stop the cleaning process.

Furthermore, the sterilization method is not limited to the method of calculating the F value as described above; for example, a sterilization method using temperature and time, as is conventionally known, may also be employed.

As described above, according to this embodiment, the control unit 60 performs forward flow processing and reverse flow processing. Forward flow processing involves passing the processing fluid through the first inlet 50a, the first outlet 50b, the heating unit 52, the second inlet 50c, and the second outlet 50d in that order. Reverse flow processing involves passing the processing fluid through the second outlet 50d, the second inlet 50c, the heating unit 52, the first outlet 50b, and the first inlet 50a in that order. This allows areas inside the heat exchangers 51a to 51c that are difficult to clean with forward flow processing to be cleaned with reverse flow processing. For example, reverse flow processing can clean the region R (see Figure 3) between the other tube sheet 72b and the shell side inlet 54c of the heat exchangers 51a to 51c. Conversely, areas inside the heat exchangers 51a to 51c that are difficult to clean with reverse flow processing can be cleaned with forward flow processing. This improves the cleanability during the cleaning process of the contents filling system 10.

Furthermore, as a modification, in the heat exchangers 51a to 51c shown in Figure 3, the processing fluid flowing from the pipe-side inlet 54a to the pipe-side outlet 54b and the flow processing fluid flowing from the shell-side inlet 54c to the shell-side outlet 54d may be supplied in opposite directions. This supply direction may be appropriately changed according to the degree of fouling in the heat exchangers 51a to 51c.

Furthermore, as another variation, the backflow treatment may be performed only on heat exchangers 51a to 51c that are heated to 60°C or higher, the temperature at which proteins denature. In this case, bypass channels (not shown) may be provided in heat exchangers 51a to 51c. This allows, for example, the first heat exchanger 51a to perform only forward flow treatment, while the second heat exchanger 51b and the third heat exchanger 51c can perform both forward and backflow treatment.

Furthermore, according to this embodiment, the first outlet 50b and the second inlet 50c of the heat exchange unit 50 are connected via a heating section 52. In this case, there is no need to prepare another medium for heating or cooling the fluid passing through the heat exchange unit 50. This reduces the installation area of the heat exchange unit 50. It also increases the heat recovery rate of the heat exchange unit 50, leading to energy savings. Moreover, it reduces the maintenance costs of the heat exchange unit 50.

Furthermore, according to this embodiment, the contents sterilization device 40 has a holding tube 53. By having the contents or a fluid such as a processing fluid remain in the holding tube 53 for a certain residence time (holding time) and while maintaining a sterilization temperature, the sterility of the fluid can be ensured.

Furthermore, in this embodiment, the pressure of the processed fluid in the flow path (space S) of the heat exchangers 51a to 51c after the holding tube 53 may be maintained higher than the pressure of the processed fluid in the other flow path (tube 73) that is being heat-exchanged. In particular, it is preferable to satisfy the above relationship with respect to the pressure of the processed fluid during the forward flow treatment immediately before the content filling process (manufacturing). This ensures the sterility of the processed fluid, especially during the content filling process.

Furthermore, according to this embodiment, the contents sterilization device 40 further includes a temperature adjustment unit 43 that adjusts the temperature of the sterilized contents to the filling temperature. This allows for appropriate control of the filling temperature of the contents by the filling device 20.

Furthermore, according to this embodiment, the processing fluid is heated by the heating unit 52 during both forward and reverse flow processing. In this case, the flow path through which the contents pass can be cleaned by CIP processing and sterilized simultaneously. This shortens the time required for SIP processing or eliminates SIP processing altogether. As a result, the product changeover time of the contents filling system 10 can be shortened, and production capacity can be improved.

Furthermore, the contents filling system 10 further includes a third circulation pipe 63c connecting the location between the contents sterilization device 40 and the filling device 20 to the first tank 42. This allows the processing fluid to circulate between the first tank 42 and the contents sterilization device 40 during both forward and reverse flow processing.

In the above explanation, a content filling system 10 using an aseptic filling method was used as an example, but it is not limited to this. For example, a content filling system using a hot filling method, where the contents are filled at a high temperature of 55°C to 95°C, is also acceptable. Furthermore, a content filling system that fills contents such as chilled beverages or alcoholic beverages that undergo SIP (steam inactivation of microorganisms) treatment after CIP (clean-in-place preservation) treatment is also acceptable.

The multiple components disclosed in the above embodiments and variations can be combined as needed. Alternatively, some components may be removed from all the components shown in the above embodiments and variations.

10 Contents filling system 20 Filling device 40 Contents sterilization device 41 Contents mixing section 42 First tank 43 Temperature control section 44 Second tank 45a-45d Contents supply system piping 50 Heat exchange unit 50a First inlet 50b First outlet 50c Second inlet 50d Second outlet 51a-51c Heat exchanger 52 Heating section 53 Holding tube 60 Control unit 90 Bottle

Claims (13)

A content filling system for filling with contents,
A sterilization device for sterilizing the contents,
A filling device for filling the contents that have been sterilized in the contents sterilization device,
The system comprises a control unit for controlling the content filling system,
The contents sterilization apparatus comprises a heat exchange unit including a heat exchanger which is at least one shell-and-tube type heat exchanger , and a heating unit connected to the heat exchange unit.
The heat exchange unit has a first inlet, a first outlet communicating with the first inlet, a second inlet, and a second outlet communicating with the second inlet.
The first outlet and the second inlet are connected via the heating section and the holding tube .
The control unit,
A forward flow treatment is performed by passing the processing fluid through the first inlet, the first outlet, the heating section, the holding tube, the second inlet, and the second outlet in that order.
A contents filling system that performs a backflow treatment by passing the processing fluid through the second outlet, the second inlet, the holding tube, the heating section, the first outlet, and the first inlet in that order. The contents filling system according to claim 1, further comprising a temperature adjustment unit for adjusting the temperature of the contents sterilized in the contents sterilization device to the filling temperature. The contents filling system according to claim 1, wherein the control unit performs the cleaning process in the order of forward flow processing, reverse flow processing, and forward flow processing. The contents filling system according to claim 1, wherein the processing fluid is heated by the heating unit during the forward flow processing and the reverse flow processing. The contents filling system according to claim 1, further comprising a first tank connected to the contents sterilization device. The contents filling system according to claim 5 , further comprising a circulation pipe connecting the position between the contents sterilization device and the filling device to the first tank. The contents filling system according to claim 6, wherein an additional heat exchanger is provided in the circulation piping, the first tank is connected to the contents sterilization device via contents supply piping, and the additional heat exchanger performs heat exchange between the processed fluid flowing through the contents supply piping and the processed fluid flowing through the circulation piping. The contents filling system according to claim 1 , wherein the fluid delivery pressure of the processing fluid passing after the holding tube in the heat exchange unit is higher than the fluid delivery pressure of the processing fluid passing before the holding tube. A method for cleaning or sterilizing a content filling system that is filled with contents,
The contents filling system comprises a contents sterilization device for sterilizing the contents, and a filling device for filling the contents that have been sterilized by the contents sterilization device.
The contents sterilization apparatus comprises a heat exchange unit including a heat exchanger which is at least one shell-and-tube heat exchanger , and a heating unit connected to the heat exchange unit, wherein the heat exchange unit has a first inlet, a first outlet communicating with the first inlet, a second inlet, and a second outlet communicating with the second inlet.
The first outlet and the second inlet are connected via the heating section and the holding tube.
The aforementioned processing method is:
A forward flow treatment step in which the treatment fluid is passed through the first inlet, the first outlet, the heating section, the holding tube, the second inlet, and the second outlet in that order,
A processing method comprising a backflow processing step of passing the processing fluid through the second outlet, the second inlet, the holding tube, the heating section, the first outlet, and the first inlet in that order. The processing method according to claim 9 , wherein the cleaning process is performed in the order of the forward flow processing step, the reverse flow processing step, and the forward flow processing step. The processing method according to claim 9 , wherein the final step of the processing method is the forward flow processing step. The alkaline cleaning process is either the forward flow process or the reverse flow process,
This includes an acidic cleaning process which is either the forward flow process or the reverse flow process,
The alkaline cleaning process is performed before or after the acidic cleaning process.
The treatment method according to claim 9 , wherein no water rinsing treatment is performed between the alkaline cleaning treatment step and the acidic cleaning treatment step. The treatment method according to claim 12, wherein the alkaline cleaning step is performed immediately after the acidic cleaning step, or the acidic cleaning step is performed immediately after the alkaline cleaning step, and the difference between the pH of the treatment fluid used in the alkaline cleaning step and the pH of the treatment fluid used in the acidic cleaning step is 8 or more and 12 or less.