Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
  • B65B55/00—Preserving, protecting or purifying packages or package contents in association with packaging
  • B65B55/02—Sterilising, e.g. of complete packages
  • B65B55/027—Packaging in aseptic chambers

Definitions

• the present invention relates to filling machines. More specifically, the present invention relates hygienic filling machines for containers.
• Such a packaging machine is used to perform a packaging process, which generally stated, includes feeding carton blanks into the machine to form cartons, sealing the bottom of the cartons, filling the cartons with the desired contents, sealing the tops of the cartons, and then off- loading the filled cartons for shipping.
• Such machines are of a more conventional type in which many of the components are driven from a common drive motor through, for example, indexing gears and cam mechanisms.
• Certain filling machines have various stations. For example, a carton forming station may be provided prior to a sterilizing station. Also a filling station and a sealing station are commonly provided. In some of these machines, the carton path may be enclosed or partially enclosed in a narrow tunnel to provide greater control over the cleanliness of the container during filling operations, etc. However, these tunnels enclosing the carton path are not necessarily optimal.
• the tunnels are difficult to clean, if cleaning is even possible due to the tight confines of the carton tunnel. As a result, automatic cleaning methods cannot be easily used with such carton tunnels. In addition, the tunnels make it difficult, if not impossible, to maintain a vertical air flow in the filling machine.
• a further disadvantage of the tunnel is that it limits visibility of the cartons in the carton path so that if a crash of the cartons occurs, it cannot be readily detected. Similarly, access is limited due to the restrictive arrangement of the tunnel enclosing the carton path.
• a related is that it creates a physical obstruction to manipulating the cartons by mechanical means. There are also problems associated with known machines having sterile air ventilation systems.
• these machines have difficulty controlling the air quality and maintaining desired air pressures within the machine.
• certain systems create recirculation paths for the air flow that allow settling regions for debris, liquid accumulation in the machine, and recontamination of the air stream and subsequently the partially packaged product.
• Another disadvantage is the inability to automatically clean and sterilize the surfaces in direct contact with the air.
• the present invention provides a hygienic filling machine which resolves the problems of the prior art.
• the filling machine has a compartmentalized clean air system for providing a unidirectional downward flow of clean air into a sterile chamber that encloses a filling station.
• An air foil divides the air supply into different air flow paths.
• the present invention also has a particle monitoring system to monitor the air quality in the sterile chamber.
• the present invention also has a microfiltrated clean air supply system for providing a highly filtered supply of clean to the sterile chamber.
• FIG. 1 is a perspective view of an embodiment of a filling machine incorporating a compartmentalized clean air system of the present invention.
• FIG. 2 is a side view of the embodiment of the filling machine of FIG. 1 incorporating a compartmentalized clean air system.
• FIG. 3 is a perspective view of the embodiment of the filling machine of FIG. 1 with components removed illustrating the orientation of an embodiment of the compartmentalized clean air system within the machine.
• FIG. 4 is another perspective view of an embodiment of a filling machine with components removed illustrating the orientation of an embodiment of the compartmentalized clean air system within the machine.
• FIG. 5 is a perspective view of an embodiment of the compartmentalized clean air system.
• FIG. 6 is a side view of an embodiment of the compartmentalized clean air system.
• FIG. 7 is a perspective view of an embodiment of an entrance wall for use with the compartmentalized clean air system of the present invention.
• FIG. 8 is a front view of an embodiment of a portion of the entrance wall of the present invention.
• FIG. 9 is another perspective view of an embodiment of the compartmentalized clean air system.
• FIG. 10 is a perspective view of an embodiment of a pump cover for use in the compartmentalized clean air system of the present invention.
• FIG. 11 is an embodiment of a screw for use in the compartmentalized clean air system of the present invention.
• FIG. 12A is a top perspective view of a portion of an embodiment of a compartmentalized clean air system of the present invention.
• FIG. 12B is a bottom perspective view of the portion of the embodiment of the compartmentalized clean air system of FIG. 12 A.
• FIG. 13 is a detail view illustrating an arrangement of the pump cover of
• FIG. 10 with the compartmentalized clean air system of the present invention.
• FIG. 14 is a graph illustrating the vertical air velocity distribution in the region of interest at an initial stage when the system is operating at maximum capacity.
• FIG. 15 is a graph illustrating the vertical air velocity distribution in the region of interest at a later stage when air filters in the system are at the end of their effective life.
• FIG. 16 is a perspective view of a schematic of an embodiment of the continuous particle monitoring system.
• FIG. 17 is a perspective view of an embodiment of a sampling probe of the continuous particle monitoring system.
• FIG. 18 is a perspective view of the embodiment of the framework of a filling machine of illustrating the orientation of an embodiment of the microfiltrated clean air supply system relative to the machine.
• FIG. 19 is a top schematic view of an embodiment of the microfiltrated clean air supply system.
• FIG. 20 is a side view in partial cross-section, illustrating various components of an embodiment of the microfiltrated clean air supply system.
• the filling machine shown generally at 100, comprises a plurality of machine stations.
• the stations are arranged sequentially within the filling machine 100 as follows: a carton magazine station 110, a carton forming station 115, a sterilizing station 120, a carton filling station 125, a carton sealing station 130 and a carton off -loading station 135.
• the cartons, gable-top cartons in the illustrated example are transported between the carton forming station 115, sterilizing station 120, carton filling station 125, carton sealing station 130, and carton off-loading station 135 by a conveyor system 140.
• the machine stations are, for example, under the control of a control unit that is disposed in a control cabinet 105.
• the control unit monitors and controls the operation of the filling machine 100.
• the illustrated system is a dual-line machine, it will be recognized that the machine 100 may be constructed as a single line machine as well.
• a supply of carton blanks are arranged at the carton magazine station 110.
• Individual carton blanks are erected and subsequently removed from the carton magazine station 110 and placed on a mandrel 145 located in the carton forming station 115. While on the mandrel 145, the erected cartons are rotated between subsequent bottom-sealing stations to form a carton having an open top and a sealed bottom. The carton thus has an open top as it enters the sterilizing station 120.
• the cartons are subject to a hydrogen peroxide spray followed by UN irradiation by an ultraviolet light assembly 155 to sterilize the interior of the carton prior to filling with product.
• Each sterilized carton is transferred from the sterilizing station 120 to the carton filling station 125 where it is filled with product.
• the product is provided to each carton through a pump and a fill pipe which are connected to receive product from a balance or intermediate storage tank 160 through a valve cluster 165.
• each carton 150 is closed and sealed at the carton sealing station 130.
• the carton sealing station 130 comprises a top folder mechanism which, for example, uses a pair of opposed wheels to temporarily fold and close the top of the carton.
• the top sealing station 130 further comprises a top sealer, such as an ultrasonic sealer, that hermetically seals the top of the carton.
• FIG. 1 also illustrates an optional screw cap applicator station 170 that is optionally provided to apply a screw cap to each carton.
• the filling machine 100 includes a plurality of doors 180 arranged to enclose the various stations.
• the doors 180 preferably have transparent portions 185 to allow observation of the operation of the individual stations.
• the compartmentalized clean air system is referenced generally at 200 and effectively encloses the fill station 125 within a positively pressurized chamber 202 having a downward flow of clean air.
• the downward flow of clean air is particularly directed about the fill pipe of the filling station so that the filling process is performed in a very hygienic atmosphere.
• at least the top folding portion of the top sealing station is also enclosed in chamber 202.
• the compartmentalized clean air system 200 includes an inlet aperture 205 that is part of an upper duct portion 210.
• the upper duct portion 210 is connected to or part of a roof portion 215 having a peak 220 in the center and sidewalls 223 that slope away from the peak 220 toward each lateral edge of the machine.
• Inlet aperture 205 is connected to a source of filtered air.
• this filtered air source may be in the form of a microfiltrated air supply system 224 that is located atop the filling machine 100 over the roof portion 215.
• the air supply system 224 has a filtered air outlet that is connected in fluid communication with the inlet aperture 205.
• Upper duct portion 210 opens to chamber 202 and includes one or more structures that assist in providing a unidirectional downward flow of sterile air through chamber 202.
• chamber 202 is defined by a pair of lateral walls that are comprised of glass doors 180 (see FIG. 1 and FIG. 2) and by a pair of transverse walls comprising an entrance wall 225 and an exit wall 230.
• the entrance wall 225 is substantially vertical and is arranged at the entrance of the chamber 202 enclosing the fill station 125.
• Entrance wall 225 includes at least one carton aperture 227 through which the cartons are conveyed by conveyor 140 into chamber 202.
• the exit wall 230 is also substantially vertical and is arranged at a distance from the entrance wall 225.
• the exit wall 230 is provided with an outlet aperture 232 through which the cartons are conveyed by conveyor 140 to exit the chamber 202.
• the chamber 202 is defined at the upper portion thereof by the roof 215 and at the lower portion thereof by table 234.
• the entrance wall 225, the exit wall 230, the side glass doors 180, the table 234, and the roof 215 enclose and define the interior chamber 202.
• a fill pipe 240 of the filling station 125 is preferable the only component of the fill pump mechanism located in the chamber 202.
• the top folding portion of the top sealing station is preferable the only portion of the top sealing station that is disposed in the chamber 202.
• a divider wall 305 may be used to separate the fill lines within the chamber 202.
• the system 200 includes various structures for directing the air flows within the chamber 202.
• an air foil 315 supported by a bracket 320 is arranged in the upper duct portion 210 and continues partially into the upper portion of chamber 202.
• the air foil 315 preferably includes a flap 325 to aid in the directing of the air flow.
• the preferred flap is fixed and its orientation has been determined by the inventors through extensive testing.
• a fill fin 330 is mounted to the entrance wall 225 within the chamber 202 by a bracket 335. The arcuate fill fin 330 acts to direct the air so that the air flow is increased proximate the fill pipe 240.
• a supply of sterile air enters the system 200 through the inlet 205.
• the air supply A is deflected within the upper duct 210 and encounters the air foil 315.
• the air foil 315 substantially divides the air supply A into two paths B and C.
• Path B is directed into the chamber 202 and path C is deflected by the flap 325 on the air foil 315 substantially downwardly along the exit wall 230 as indicated by arrow D.
• a portion of the air from path B, referenced with arrow E is captured and directed by the fill fin 330.
• the air in path E experiences an increase in velocity as a result of the curvature of the fill fin 330.
• a vertical air bath exists at a height of approximately two inches above open carton tops.
• the air bath is indicated by arrows N.
• the air passes out through the bottom of the filling machine 100 as indicated by arrows F.
• the filling station and the top folding portion of the top sealing station are the regions requiring the greatest amount of hygienic control.
• the top folding portion of the top sealing station 130 effectively retains the top flaps of each container in a temporarily closed condition before final sealing by an ultrasonic sealer 332 located exterior to the chamber 202. As such, the cartons are filled and effectively closed within chamber 202 and are never subsequently opened until opened by the consumer.
• the continuous downward flow of air in the chamber 202 which results from the construction of the compartmentalized clean air system 200 as described, increases the hygiene of the chamber 202. Also, the increased velocity air flow in the region of the fill pipe 240 referenced at arrow E has the advantage of overcoming localized turbulence and recirculation caused by machine operation.
• the carton is lifted rapidly to meet the fill pipe 240 and subsequently lowered as the carton is filled. While such a filling operation is beneficial for filling the cartons, the sudden and rapid movements of the carton and the lifter create local turbulence which can introduce contaminants into the chamber 202 and the hygienic region of the filling station 125.
• the fill fin 330 is constructed and arranged to increase the air flow in the turbulent region of the moving carton.
• the air flow indicated at arrow E is sufficient to maintain a continuous downward flow in the turbulent region so that contaminants are kept out of the hygienic filling station 125.
• a grate in table 234 which allows the sterile air to flow from the chamber 202 to an exterior portion of the machine 100.
• a vacuum source may be connected to receive air passing through the grate thereby further reducing any turbulence proximate the table 234.
• the open architecture of the clean air system 200 reduces turbulence from the inlet 205, throughout the chamber 202, and out the bottom of the filling machine 100.
• the divider wall 305 separates the two carton paths from each other. The arrangement of the divider wall 305 between the two carton paths advantageously reduces cross-turbulence.
• an additional advantage and benefit of the embodiment of the compartmentalized clean air system 200 described above is the fact that it allows automatic cleaning methods and equipment to be used to clean and sterilize the stations and the filling machine 100.
• an automatic cleaning system referenced generally at 440 is provided within the filling machine 100.
• the cleaning system 440 includes a plurality of spray balls 445 and spray jets 450.
• the spray balls 445 and spray jets 450 comprehensively spray the stations, and in particular, the filling station 125 and the sealing station 130, with a cleaning solution.
• the compartmentalized clean air system 200 of the present invention is arranged such that the components thereof do not interfere with the automatic cleaning system 440.
• the entrance wall 225 comprises several cut-out portions. More particularly, a pair of pump cutouts 545 are provided in the upper part of the entrance wall 225 at the intersection with the roof 215. Access slots 550 are provided at the bottom of the entrance wall 225 to allow the conveyor 140 to pass through the entrance wall 225. Finally, the carton pass-through apertures 227 are located at a lower portion of the entrance wall 225.
• the carton apertures 227 include a top lip 560 and side lips 565 arranged around the apertures 227.
• FIG. 7 illustrates a substantially straight cut for the region of the top lip 560.
• FIG. 8 provides a different possible shape.
• the top lip 560 and the side lips 565 are formed to approximately replicate the profile of carton 567.
• the chamber 202 may be kept more hygienic by restricting the size of the aperture 227 through which contaminants can enter the chamber 202.
• top lip 560 is angled to direct any liquid disposed thereon to a lateral side of the machine.
• the exit apertures 232 of the exit wall 230 are similarly constructed.
• the exit apertures 232 may substantially conform to the shape of the top of a carton.
• a pair of pump covers 570 are connected to the entrance wall 225 at the pump cut-outs 545.
• One embodiment of a pump cover 570 is shown in FIG. 10.
• the pump cover 570 is provided to encompass part of the filling station 125, namely the fill pump, while allowing the fill pipe 240 to project through the pump cover 570 into the chamber 202. In this manner, the generally non-hygienic, moving components of the fill pump are not allowed to contaminate the chamber 202 with debris.
• the pump cover 570 comprises a shroud 580 that encloses the fill pump and a fill pipe aperture 610 that is disposed at a bottom portion 585. As shown, the bottom portion 585 includes angled sections 590 and a substantially horizontal section 595. A top flange 600 is arranged at an edge of the shroud 580 and forms an interface with the roof 215. The fill pipe aperture 610 is formed in the horizontal section 595. The aperture 610 is appropriately dimensioned to allow the fill pipe 240 to pass through. The aperture 610 may be oversized to allow for positional tolerances with respect to the location of the fill pipe 240 relative to the pump cover 570.
• a gasket (not shown) may be used as a seal between the outside diameter of the fill pipe 240 and the inside diameter of the aperture 610.
• a flexible fill pipe sleeve may be provided.
• the peak 220 of the roof portion 215 is located approximately in the center to provide a slope away from the center to each lateral edge.
• the slope is preferably finished so that a grain direction indicated by arrow G is provided.
• This grain direction may be established by creating parallel grooves in the grain direction G. This can be done by grinding or other known finishing techniques.
• the combination of the slope and the grain directing grooves facilitates the removal of fluid and other spills that may fall onto the roof portion 215 down to the edges of the roof 215.
• a pair of roof cut-outs 650 are formed in the roof portion 215.
• a flange 660 substantially surrounds the roof cut-outs 650 in the roof portion 215.
• the pump cover 570 forms an interface with the roof portion 215 at the cut-outs 650 and the flanges 660. To compensate for accumulated tolerances, the pump cover 570 is preferably not directly connected to the roof portion 215. Instead, a labyrinth-type sealing arrangement 715 as illustrated in FIG. 13 is provided.
• the flange 660 on the roof portion 215 includes an inverted J-shaped lip 720.
• the top flange 600 of the shroud 580 of the pump cover 570 is situated beneath the inverted J-shaped lip 720.
• a gap 725 is provided between the top flange 600 and the lip 720.
• the gap 725 allows air to flow out of the chamber 202 due to the positive pressure maintained in the chamber 202. Such an outward flow is indicated by arrow P.
• the labyrinth-type sealing arrangement 715 allows air to escape, it does not allow contaminants to enter the chamber 202 through this region. As shown by arrows Q, contaminants from outside cannot enter.
• a lifting mechanism 800 for raising and lowering a door panel 805 on the exit wall 230 is illustrated.
• the door panel 805 is periodically raised and lowered to service the components of the top sealing station.
• the lifting mechanism 800 is operated to lift the door panel 805 a sufficient distance to provide adequate clearance for the ultrasonic top sealer 332 to swing upwardly in an arc to facilitate maintenance and assembly. It is also automatically cycled during cleaning to allow for cleaning access to the top sealer 332.
• the divider wall 305 which provides a hygienic barrier between the two carton conveyor paths, further includes an arched cut-out 815.
• the door panel 805 can be raised using the lifting mechanism 800.
• the arched cut-out 815 allows the sealing station 130 to swing upwardly in an arc corresponding to the arched cut-out 815 for cleaning or maintenance when required.
• the apparatus and arrangement of the compartmentalized clean air system provides segregated positive pressure zones within the filling machine 100. Such an arrangement provided varying levels of hygiene throughout the filling machine 100. For example the relative pressures for regions illustrated from left to right in FIG.
• the pressure at the carton off-loading station 135 is approximately atmospheric; the pressure in the region of the carton sealing station 130 is greater than atmospheric; the pressure in the region of the carton filling station 125 is a relative maximum and therefore greater than that of the carton sealing station 130 and the sterilizing station 120 and the carton forming station 115; finally, the pressure at the carton magazine station 110 is again atmospheric.
• the carton filling station 125 which requires the greatest hygiene is maintained at the relative maximum pressure and has a positive vertical downward air bath in the chamber 202.
• FIGs. 14 and 15 graphically illustrate the vertical air velocity distribution from the interface between the sterilizing station 120 and the carton filling station 125 to the carton top sealing station 130.
• the region of interest is also delimited by the center panel 305 and the door 180.
• FIG. 14 illustrates the vertical air velocity in the region of interest at an initial stage when the system is operating at maximum capacity.
• FIG. 15 illustrates the vertical air velocity in the region of interest at a later stage when air filters in the system are at the end of their effective life. Comparison of the two figures shows how the vertical air velocity decreases as the filters degrade. However, the velocity distribution remains basically proportionate so that critical areas (for example, near the fill pipe) have the highest velocity air.
• FIGs. 3, 5, 6, 16 and 17 an embodiment of a continuous automatic particle monitoring system is illustrated generally at 350.
• FIG. 16 schematically illustrates an embodiment of the automatic and continuous particle monitoring system 350 and the relative orientation of the components of the system.
• Primary components of the system include a particle counter 360.
• the particle counter 360 is preferably arranged in a self-contained housing unit 365.
• the counter 360 also has a vacuum pump 370 and an interface connection 380 to a programmable logic controller (PLC) 385 located in the control unit cabinet 105 of the filling machine 100 (see FIG. 2).
• PLC programmable logic controller
• the particle counter 360 is preferably configured for 24 volt operation.
• the pump 370 creates a vacuum which generates a metered flow of one cubic foot per minute (cfm) into the particle counter 360. This flow is indicated by arrows referenced N in FIG. 16. The metered flow may range from approximately 0.1 cfm to 2.0 cfm.
• the vacuum created by the pump 370 draws an aerosol sample into the particle counter 360 through a sampling probe 390 connected to the particle counter 360.
• the sampling probe 390 is connected in fluid communication with the particle counter 360 by a particle sampling line 395.
• the particle sampling line 395 is preferably 0.25 inch diameter, non-shedding Bevaline tubing available from Climet Instruments Company of Redlands, California.
• the particle counter 360 incorporates various features.
• the particle counter 360 preferably incorporates laser diodes.
• the particle counter 260 preferably operates using time-averaging of the particle counts.
• the time-averaging is a beneficial feature incorporated in the particle counter 360.
• the particle counter 360 is less susceptible to non-representative transient aerosol generation bursts which may distort an accurate particle count.
• alarm limits for indicating an excessive particle count are provided.
• the interface connection 380 to the PLC 385 provides power, input/output
• the PLC 385 is used to help control the filling machine 100 in response to the information provided by the particle counter 360.
• a particle counter sampling probe is arranged in an isoaxial direction (in-line with the predominant air flow direction).
• an arrangement might likely result in the ingestion of undesirable contaminants into the particle counters. For example, cleaning solution or product could enter the probe and cause damage to the sensitive particle counters.
• the sampling probes 390 in the preferred embodiment are arranged in an anisoaxial, anisokinetic configuration in the filling machine.
• the placement of the sampling probes 390 near the filling system 125 is advantageous since this area requires the greatest hygiene, since the product is exposed to open air while being dispensed from the fill pipe 240 to the carton.
• the probes 390 are specifically designed to protect the sensitive particle counters 360 from the accidental ingestion of product, water, or cleaning chemicals.
• the probe 390 is arranged in the sterile chamber 202 near the filling system 125 of the filling machine 100 (see FIG. 6).
• the probes 390 are shaped and arranged to sample the air from the sterile chamber 202 in an anisoaxial, anisokinetic manner while still providing an acceptable aspiration efficiency that deviates from the efficiency of an in-line probe by only a minimal amount.
• the inventor herein performed extensive calculations and experiments to verify that the probe configuration of the present invention operates within acceptable levels.
• the probe 390 typically samples particle counts for aerodynamic particle diameters of greater than or equal to 0.3 ⁇ m. Since the probe is mounted in an anisokinetic and anisoaxial manner, the sampling is not at 100% aspiration efficiency. However, the inventor of the present application has performed theoretical calculations to evaluate the aspiration efficiency of the total system.
• the calculations take into account the theoretical aspiration efficiencies including probe effects, line losses, etc. The calculations prove that the effect of the anisoaxial and anisokinetic sampling is negligible with respect to line losses for the particle sizes of interest.
• the inventor has calculated the aspiration efficiencies of the preferred sampling probe 390 such that the probe may be oriented to protect the counters 360 from the ingestion of splash product, cleaning chemicals, etc., and to allow the probe 390 to drain fluid while still providing an acceptable aspiration efficiency.
• a positive blowdown air flow within the sterile chamber 202 (illustrated in FIGs. 6 and 16, referenced by arrows E) has a particulate count which is measured by the counters 360 by utilizing the probes 390 arranged within the sterile chamber 202.
• the particle counter housing unit 365 may be arranged outside the sterile chamber 202. In the preferred embodiment shown in FIGs. 3 and 6, the housing unit 365 is mounted above the sterile chamber 202 in between the clean air system 200 and the clean air supply system 224.
• the sampling lines 395 between the probe 390 and the particle counter 360 are kept relatively short to provide more accurate total sampling efficiencies.
• the short sampling lines 395 help to compensate for some of the reductions in the aspiration efficiency due to non-isoaxial, non-isokinetic sampling.
• the sampling probe 390 comprises a bent tubular body having a sampling port 400 into which particles are drawn by the vacuum created by the pump 370 in the counter 360.
• the probe 390 also includes a mounting plate 405 and a sampling line connector portion 410.
• the sampling line connector portion 410 is connected to the sampling line 395.
• the mounting plate 405 includes a securement 420, for example, a bolt.
• the securement 420 enables the probe 390 to be maintained in a fixed position.
• the mounting plate 405 also incorporates a locating pin 430.
• the locating pin 430 inserts into a preselected, cooperating locating hole (not shown) to ensure that the probe 390 is mounted in the proper location and orientation within the filling machine 100 to maintain the aspiration efficiency and protect the particle counters.
• FIG. 1 illustrates that two conveyor lines 140 are used in the embodiment of the filling machine 100.
• the dividing wall 305 is arranged in the sterile chamber 202 of the filling machine 100 as shown dashed in FIG. 16.
• Similar particle monitoring systems 350 are arranged on each side of the dividing wall 305, and therefore provide independent particle monitoring of each conveyor path 140. This is advantageous because one path may be contaminated while the other is operable and need not be shut down.
• the embodiment of the continuous and automatic particle monitoring system 350 is additionally advantageous in that it is connected to the control unit 105 of the filling machine 100. When a preselected particle concentration is exceeded, an alarm will sound and the machine shuts down automatically. As a result, the operator can closely monitor the operation of the filling machine 100 and maintain quality control of filling operations.
• An additional advantage of the continuous particle monitoring system 350 is that it can monitor particles during operation and then be rendered dormant during the automatic cleaning and sterilization of the stations in the filling machine 100.
• the microfiltrated clean air supply system is referenced generally at 224 and includes the inlet 206 and the outlet 226.
• the inlet 206 is covered by an inlet door 242.
• the inlet door 242 preferably has a plurality of louvers 244 formed therein to allow the intake of air into the clean air supply system 224.
• the clean air supply system 224 comprises a housing 245.
• the housing module 245 is preferable brushed or polished stainless steel 304 with the seams being minimized.
• the housing 245 extends from the inlet 206 to the outlet 225.
• An outlet door 246 is arranged near the outlet 225 and has louvers 244 like those formed in the inlet door 242.
• the housing 245, the outlet door 246 and the inlet door 242 enclose and define an interior chamber 248.
• the interior chamber 248 of the housing 245 is described further below with reference to FIG. 19.
• An adjustable damper mechanism 249 is also illustrated in FIGS. 18-20. The arrangement and operation of the damper mechanism 249 is discussed below with reference to FIG. 20.
• the system 224 includes the louvered inlet doors 242 covering the inlet 206.
• the louvered inlet doors 242 include an external aesthetic portion with a set of internal V-shaped louvers, the combination of which provides an impenetrable path for any directed liquid spray from entering the inlet doors 242.
• a first plurality of filters 250 arranged transverse to the incoming air flow indicated by arrows referenced A is provided in the inlet 206 of the clean air supply system 224.
• Coalescing filters 252 are preferably mounted in the inlet door 242.
• the combination of the coalescing filters 252 and louvers 244 with a labyrinth-style sealing arrangement 255 discussed below with reference to FIG.
• the first plurality of filters 250 includes a first
• ASHRAE prefilter 260 having a collection efficiency within an approximate range of 30% - 60%).
• a second ASHRAE prefilter 265 having a collection efficiency within an approximate range of 90-95%> is also arranged downstream with respect to the first ASHRAE prefilter 260 in the inlet 206 of the housing 245.
• a framework of the 95% ASHRAE filter 265 may be sealed against the housing with a foam gasket. The combination of the two levels of ASHRAE prefilters 260, 265 collects most of the mold and yeast before it ever reaches the final filters.
• the ASHRAE prefilters 260, 265 include an antimicrobial agent to prevent mold growth on the filter media.
• the antimicrobial agent may be impregnated into the filter 260, 265.
• the ASHRAE filters 260, 265 may be treated with an antimicrobial spray or incorporate a BioStat weave.
• an Aegis Antimicrobial system is sold as a complement to the 30% ASHRAE filter 260 manufactured by Tri-Dim Filters of Elgin, Illinois.
• an Antimicrobial Treatment is sold as a complement to the 95% ASHRAE filter 265 manufactured by Flander's Filters of Washington, North Carolina. Consequently, the collected mold is inhibited and then disposed of by periodic replacement of the ASHRAE prefilters 260, 265 which extends the life of the final filters by protecting them from potential "mold grow-through.”
• a blower chamber 280 is also provided within the housing 245 of the microfiltrated clean air supply system 224.
• a blower 285 is preferably mounted in the blower chamber 280 in a known shock absorbing manner to reduce vibrations.
• the blower 285 is a direct drive, high-output type capable of producing 2,000 cfm ⁇ 20%> over the required range of static pressure.
• blower 285 includes an exhaust port 290 connected in fluid communication with an aperture 295 in a dividing wall 300.
• the diffuser plate 306 is arranged in front of the blower 285 to distribute the air.
• the diffuser 306 is preferably perforated metal, for example, 16 gauge stainless steel 304, formed to a preselected shape and appropriately arranged in the housing 245.
• FIG. 19 illustrates a portion of a plurality of perforations 310 formed in the diffuser 306.
• the perforations 310 comprise approximately 0.25 inch holes arranged on 0.375 inch center stagger spacings to provide approximately 40%> porosity.
• diffused air indicated by arrows referenced D flows through a second plurality of filters, including 95% collection efficiency DOP prefilters 316.
• the 95% DOP prefilters 316 have a collection efficiency of 95% for 0.3 ⁇ m diameter particles.
• the 95% DOP prefilters 316 may be secured within the housing 245 by known sealing means familiar to those skilled in the art.
• the 95% DOP filters 316 are sealed with foam in a gasket seal in a stainless steel 304 frame.
• the 95% ASHRAE prefilters 265 are also sealed with foam.
• the prefilters 260, 265, 316 preferably are constructed of a hydrophobic material, for example, a fiberglass media.
• An air gap 321 is illustrated between the 95% DOP prefilters 315 and final filters 331.
• Final filters 331 are preferable held by a known gel/knife-type seal to provide airtight seal of the final filters 331 within the housing 245.
• the final filters 331 preferably have a collection efficiency of at least 99.99999% for 0.12 ⁇ m diameter particles.
• Pleats in the final filter 331 are mounted in a vertical orientation.
• the preferred filters have the following listed sizes and collection efficiencies, and are available from known suppliers.
• the preferred filters include: coalescing prefilters 252 (24" x 24" x 2") manufactured by AAF Snyder General Corp., Louisville, Kentucky; 50%> ASHRAE rigid pleat prefilter 260
• the aforementioned embodiment of the microfiltrated clean air supply system 224 provides a level of filtration to yield a supply of high quality air even in challenging (dirty) environments.
• the air quality of air entering the filling machine can be estimated from the following ambient air concentrations.
• the housing 245 is constructed and arranged to provide an operator with visual and physical access to the internal components of the microfiltrated clean air supply system 224 contained within the housing 245.
• a transparent view port 351 for the blower 285 is provided. Additional view ports are provided as needed.
• a further view port 356 for allowing visual inspection of the final filter 331 and the bypass damper 249 is formed in the housing 245 as shown in FIG. 18.
• FIG. 20 An embodiment illustrating various components of the microfiltrated clean air supply system 224 is shown in FIG. 20 in partial cross-section.
• the coalescing filters 252 and the ASHRAE prefilters 260, 265 are accessible from the side via the inlet doors 242.
• Access to the blower 285 can be gained from the inlet doors 242 and a removable top panel 361 covering an aperture in the top of the housing 245.
• the 95% DOP prefilters 316 can be serviced via a second top access panel 371.
• the final filters 331 are similarly accessible via a third top access panel 376.
• the housing module 245 provides operator access to the internal components while still protecting the filters from harsh external environments, overhead drainage and dripping condensate, as well as product splashes and physical damage.
• FIG. 20 illustrates an additional arrangement for preventing even a direct external spray of liquid from entering either the inlet doors 242 or the outlet door 246.
• the louvers 244 in the doors 242, 246 form a labyrinth-type seal when combined with a plurality of inverted V-shaped deflectors 381 arranged inside the doors 242-246.
• the cooperative arrangement of the louvers 244 and the deflectors 381 inside the doors 242, 246 creates an obstructive path to prevent a direct spray of water, cleaning solution or any liquid from entering the housing 245 via the doors 242, 246.
• a screen mesh 386 is located adjacent the louvers 244 to prevent insects or small debris or particles from entering.
• FIG. 20 also illustrates the bypass damper mechanism 249 incorporated in the housing module 245.
• the damper 249 preferably has two positions. Both alternatives are illustrated in FIG. 20.
• the bypass damper 249 In a first open position used during normal operation of the filling machine 100, the bypass damper 249 is preferably arranged at approximately a 60° angle along an angled surface 390. When in this open position, the damper 249 deflects the filtered air indicated by arrows C in FIG. 19 downward into the sterile chamber 180 of the filling machine 100.
• the damper 249 also has a second, closed position that can be selected to isolate the sensitive filters during the cleaning operation of the filling machine 100 or during downtime.
• the damper 249 When this second, closed position is selected, the damper 249 is in a horizontal position sealing the outlet 226 as shown in FIG. 20.
• the damper 249 protects the filters of the microfiltrated air supply system 224 by effectively sealing the outlet 225 and deflecting cleaning solution back down into the filling machine 100.
• the bypass damper 249 is provided with an actuator, for example, a pneumatically-actuated control arm 400. The position of the damper 249 can thereby be selected for simultaneous cleaning bypass control and filter protection or normal operation.
• the damper 249 and actuator 400 are internally mounted in the housing 245.
• the actuator 400 may be externally mounted.
• a sensor 410 is also provided to detect or validate the position of the damper 249. Also, the location of the damper 249 may be visually determined via the further view port 356 (see FIG. 1).
• the bypass damper 249 facilitates the automated cleaning of the filling machine 100. The pneumatically actuated damper 249 closed during cleaning cycles thereby protecting the final filters 331 from the spray of cleaning solution discussed below.
• FIG. 20 also illustrates a plurality of pressure gauges for monitoring the operation of the filters by detecting pressure changes across the filters.
• the opening of the filter doors may be detected by the pressure gauges.
• the plurality of pressure gauges include a first gauge 435 connected to provide a visual indication to the operator of the pressure in the sterile chamber 202. Adjustable maximum and minimum alarm levels are incorporated into the gauges which interface with a programmable logic controller (PLC) 441 in the control cabinet 105 (see FIG. 2) of the machine 100 to inform the machine when the acceptable levels have been breached.
• PLC programmable logic controller
• a second gauge/sensor for detecting a change in pressure across the 99.99999%) PSL final filter 331 is also provided. Pressure ports provide the input to gauges. Similarly, a corresponding second gauge 445 is connected to display the change in pressure across the 99.99999%) PSL 331, 316. Likewise, a third gauge 455 is connected to display the change in pressure across the 95% DOP Prefilter 316. In addition, a corresponding fourth gauge 465 is provided for detecting and displaying a change in pressure across the 95% ASHRAE prefilter 265.
• the displayed pressure readings can enable the operator to monitor performance of the internal components in the housing 245. For example, a change of pressure across the prefilters may indicate a filter change is needed, a major leak or a lack of a filter. Also, a change of pressure across the final filter 331 can indicate similar problems.
• the insertion of a filter of inferior quality, for example, a HEPA filter instead of a VLSI II filter as specified in the preferred embodiment above may be indicated by the second gauge 445.
• varying degrees of alarms for each filter can be included. As shown in FIG. 20, the gauges 435, 445, 455, 465 are mounted on an exterior panel 475 at an angle that is easily visible to the operator.

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• Engineering & Computer Science (AREA)
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• Basic Packing Technique (AREA)
• Separation By Low-Temperature Treatments (AREA)
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• 1998
  • 1998-03-25 DE DE19882237T patent/DE19882237B4/de not_active Expired - Lifetime
  • 1998-03-25 AU AU67755/98A patent/AU6775598A/en not_active Abandoned
  • 1998-03-25 WO PCT/US1998/005926 patent/WO1998043878A1/en active Application Filing
  • 1998-03-25 JP JP54179198A patent/JP4386969B2/ja not_active Expired - Lifetime
• 1999
  • 1999-09-24 NO NO19994657A patent/NO315740B1/no not_active IP Right Cessation

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