WO2020062889A1 - 一种用于无菌灌装生产线的杀菌工艺 - Google Patents

一种用于无菌灌装生产线的杀菌工艺 Download PDF

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WO2020062889A1
WO2020062889A1 PCT/CN2019/087199 CN2019087199W WO2020062889A1 WO 2020062889 A1 WO2020062889 A1 WO 2020062889A1 CN 2019087199 W CN2019087199 W CN 2019087199W WO 2020062889 A1 WO2020062889 A1 WO 2020062889A1
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Prior art keywords
temperature
circulation system
hot water
water circulation
temperature hot
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PCT/CN2019/087199
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English (en)
French (fr)
Inventor
茅嘉惠
杨亚军
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江苏新美星包装机械股份有限公司
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Priority to EP19866519.2A priority Critical patent/EP3858783A4/en
Priority to JP2021516979A priority patent/JP2022502319A/ja
Publication of WO2020062889A1 publication Critical patent/WO2020062889A1/zh

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/02—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor using physical phenomena
    • A61L2/04—Heat
    • A61L2/06—Hot gas
    • A61L2/07—Steam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B67—OPENING, CLOSING OR CLEANING BOTTLES, JARS OR SIMILAR CONTAINERS; LIQUID HANDLING
    • B67C—CLEANING, FILLING WITH LIQUIDS OR SEMILIQUIDS, OR EMPTYING, OF BOTTLES, JARS, CANS, CASKS, BARRELS, OR SIMILAR CONTAINERS, NOT OTHERWISE PROVIDED FOR; FUNNELS
    • B67C7/00—Concurrent cleaning, filling, and closing of bottles; Processes or devices for at least two of these operations
    • B67C7/0073—Sterilising, aseptic filling and closing
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/0005—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts
    • A61L2/0011—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts using physical methods
    • A61L2/0023—Heat
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/0005—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts
    • A61L2/0082—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts using chemical substances
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/0005—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts
    • A61L2/0082—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts using chemical substances
    • A61L2/0088—Liquid substances
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/02—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor using physical phenomena
    • A61L2/04—Heat
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/16—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor using chemical substances
    • A61L2/18—Liquid substances or solutions comprising solids or dissolved gases
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/24—Apparatus using programmed or automatic operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B9/00—Cleaning hollow articles by methods or apparatus specially adapted thereto 
    • B08B9/02—Cleaning pipes or tubes or systems of pipes or tubes
    • B08B9/027—Cleaning the internal surfaces; Removal of blockages
    • B08B9/032—Cleaning the internal surfaces; Removal of blockages by the mechanical action of a moving fluid, e.g. by flushing
    • B08B9/0321—Cleaning the internal surfaces; Removal of blockages by the mechanical action of a moving fluid, e.g. by flushing using pressurised, pulsating or purging fluid
    • B08B9/0325—Control mechanisms therefor
    • 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
    • B65B55/04—Sterilising wrappers or receptacles prior to, or during, packaging
    • B65B55/10—Sterilising wrappers or receptacles prior to, or during, packaging by liquids or gases

Definitions

  • the invention relates to a sterilization process for an aseptic filling production line.
  • the material sterilizer and the aseptic water sterilizer are indispensable supporting equipment, and must be operated at the same time to provide the corresponding processing medium for the aseptic filling machine.
  • Material sterilizer is used for instant sterilization of product materials at 138 ⁇ 140 °C, which can effectively kill E. coli, mold, pathogenic bacteria, etc. in the material, and at the same time destroy the growth of microorganisms and spores, so that after filling The final product can achieve long-term transportation and storage purposes, extending the shelf life of beverage products.
  • the sterile water sterilizer is used in aseptic filling production. After sterilizing the beverage packaging bottles and caps with disinfectant, they are rinsed with sterile water to ensure that the packages used before product filling and capping are guaranteed. The residue in the material was rinsed clean without any residue, and the production of sterile water was also thoroughly sterilized at 140 ° C using ultra-high temperature instant sterilization equipment for the water entering the filling environment.
  • the medium for 140 ° C sterilization and heat transfer of the material sterilizer is high-temperature hot water.
  • the heating temperature of the high-temperature section is as high as 143 to 145 ° C, which is higher than the 140 ° C sterilization temperature of ordinary sterile water sterilizers.
  • the pipeline in the hot water system of the material sterilizer is a fully enclosed structure with pressure, which fully meets the aseptic process conditions.
  • the final temperature of the high-temperature hot water after heat exchange with the material is between 50-60 ° C, and the high-temperature hot water is used to cool down the material after the reflux; in the sterile water sterilizer, the sterile water The operating temperature is 50 ° C.
  • the high-temperature hot water at 50-60 °C has a poor cooling effect on the materials, and a large amount of pure water is heated to the sterilization temperature and then cooled to the use temperature, which consumes large amounts of pure water and energy.
  • the purpose of the present invention is to provide a sterilization process for an aseptic filling production line. After the high-temperature hot water generated in the high-temperature hot water circulation system is subjected to heat preservation and sterilization treatment, it is directly converted into sterile water supply and used to cool the materials. After that, it enters the sterile water circulation system through the first pipeline. At the same time, the flow rate of self-supplying sterile water in the sterile water circulation system is gradually reduced, and in the sterile water circulation system, as the production capacity is gradually reduced, the amount of heat exchange steam used for heating and sterilization will also be reduced, effectively reducing The energy consumption index of steam, ice water, and tower water during the operation of the sterile water circulation system greatly reduces the operation input cost.
  • the sterile water circulation system can always ensure the normal operation of small flows, the sterile environment is not damaged, and the sterile water The smaller the self-flow reduction, the lower the overall operating energy consumption; meanwhile, the high-temperature hot water circulating in the high-temperature hot water circulation system will also be reduced.
  • purified water at normal temperature it is directly used for and The high-temperature materials in the material circulation system perform heat recovery and heat exchange.
  • the newly-added normal temperature purified water is lower than the temperature of the normal reflux high-temperature hot water.
  • the heat recovery and cooling capacity of the materials will be better, and the material temperature can be lowered. It can effectively reduce the energy consumption of media such as tower water, ice water, etc.
  • a sterilization process for an aseptic filling production line includes the following steps:
  • a first pipeline is provided between the high-temperature hot water circulation system and the sterile water circulation system, and the high-temperature hot water portion after heat exchange with the material is transferred to the sterile water circulation system through the first pipeline;
  • step (2) purified water is replenished to the sterile water circulation system, and the purified water is circulated and warmed to the second sterilization temperature in the sterile water circulation system.
  • step (2) the communication states between the first pipeline and the high-temperature hot water circulation system and the sterile water circulation system are cut off, and then the first pipeline is passed into the first pipeline.
  • the high-temperature water vapor having the second sterilization temperature is maintained until the high-temperature water vapor in the first pipeline is maintained at the first temperature for a second period of time.
  • step (2) pure water is replenished to the material circulation system, and pure water is also replenished to the high-temperature hot water circulation system, so that the purified water is separately in the material circulation system and the high temperature.
  • the temperature is raised to the second sterilization temperature.
  • the first path directly exchanges heat with steam
  • the second path first exchanges heat with steam.
  • the first path is heat-exchanged, and then returned to the first path before being exchanged with steam, and the first path and the second path are exchanged with materials after the heat is exchanged, and the first path and the material are exchanged.
  • the temperature during heat exchange is the first set temperature.
  • the temperature is raised to the first sterilization temperature, and the first period of time is maintained.
  • the first set temperature is made to be within 3 ° C. higher than the temperature of the material to be exchanged with the first circuit.
  • the high-temperature hot water that has been heat-exchanged with the material enters the sterile water circulation system through the first pipeline and is used after the temperature is lowered.
  • step (4) the supplemented normal temperature pure water is mixed with high temperature hot water to directly exchange heat with the material to cool the material.
  • the present invention is a sterilization process for an aseptic filling production line, and the high temperature hot water generated in the high temperature hot water circulation system is subjected to heat preservation and sterilization treatment. After that, it is directly converted into sterile water supply and used, after the material is cooled, it is passed into the sterile water circulation system through the first pipeline.
  • the flow rate of self-supplying sterile water in the sterile water circulation system is gradually reduced, and in the sterile water circulation system, as the production capacity is gradually reduced, the amount of heat exchange steam used for heating and sterilization will also be reduced, effectively reducing
  • the energy consumption index of steam, ice water, and tower water during the operation of the sterile water circulation system greatly reduces the operation input cost.
  • the sterile water circulation system can always ensure the normal operation of small flows, the sterile environment is not damaged, and the sterile water
  • the smaller the self-flow reduction the lower the overall operating energy consumption; meanwhile, the high-temperature hot water circulating in the high-temperature hot water circulation system will also be reduced.
  • purified water at normal temperature By adding purified water at normal temperature to the high-temperature hot water circulation system, it is directly used for and The high-temperature materials in the material circulation system perform heat recovery and heat exchange.
  • the newly-added normal temperature purified water is lower than the temperature of the normal reflux high-temperature hot water.
  • the heat recovery and cooling capacity of the materials will be better, and the material temperature can be lowered. It can effectively reduce the energy consumption of media such as tower water, ice water, etc.
  • FIG. 1 is a schematic structural diagram of an aseptic filling production line to which the process of the present invention is applied.
  • Sterile heat Constant pressure valve for water supply 19, Sterile hot water aseptic T-shaped diaphragm valve; 20, Constant pressure valve for material hot water system; 21, SIP / shielded steam inlet valve; 22, Quick drain valve for steam condensate; 23, SIP / Shielded steam outlet valve; 24, constant pressure valve of sterile water cooling system; 25, first pipeline; 26, first heat exchanger; 27, second heat exchanger; 28, third heat exchanger; 29, Fourth heat exchanger; 30, fifth heat exchanger; 31, sixth heat exchanger; 32, seventh heat exchanger; 33, eighth heat exchanger; 34, ninth heat exchanger; 35, tenth Heat exchanger; 36, the first steam exchange Heater; 37. Second steam heat exchanger.
  • a first pipeline 25 is added between the high-temperature hot water circulation system and the aseptic water circulation system.
  • the second sterilization temperature is 143 ° C.
  • the first pipeline 25 is SIP cleaned, and the medium is high-temperature water vapor of 143 ° C (second sterilization temperature).
  • the steam condensate quick-release valve 22 and the steam SIP discharge valve 12 are both opened, and discharged quickly. Steam condensate. After the condensate is discharged, the steam condensate quick-release valve 22 is closed separately. At the same time, the SIP / shielded steam inlet valve 21 is opened. SIP high-temperature pure steam enters the entire first pipeline 25.
  • the water supply is provided by the material SIP tank 4 and the hot water tank 6, respectively.
  • the sterile water in the material SIP tank 4 passes through the fourth heat exchanger 29 and degassing in sequence.
  • the homogenizer 5, the fifth heat exchanger 30, and the sixth heat exchanger 31 heat up, and then pass the seventh heat exchanger 32, the eighth heat exchanger 33, and the ninth heat exchanger 34 to cool down, and then go through aseptic filling.
  • the machine 17 returns to the material SIP tank 4; the sterilized water in the hot water tank 6 heats up through the seventh heat exchanger 32 and the second steam heat exchanger 37 in turn, and then adjusts the first device through the tenth heat exchanger 35.
  • the second steam heat exchanger 37 is used to heat the sterile water in the material circulation system and the high-temperature hot water circulation system to 143 ° C (second sterilization temperature), and maintain the temperature for 30 minutes.
  • the sterile water side is in a normal supply state.
  • the sterile water outlet cut-off valve 14 is closed, and the system water is supplied by the sterile water balance tank 15 while the sterile water return cut-off valve 16 is closed.
  • the entire system generates a circuit.
  • the temperature is reduced to 50 ° C without interruption It is supplied to the aseptic filling machine 17; and the entire first pipeline 25 is in a state of being shielded at a temperature above 125 ° C. using pure steam.
  • the material-side material outlet cutting tank valve 3 is closed, and the system feed is provided by the material balance tank 2.
  • the material return cutting tank valve 1 is closed, and the return flow is cut back to the material balance tank 2 at the same time.
  • the entire system generates a loop.
  • Material sterilization production starts, the material enters the material balance tank 2 and is buffered. Then it is heated to 75 ° C by the material degassing heat exchanger and enters the degassing homogenizer 5. After being processed in the degassing homogenizer 5, it returns to the fifth heat exchanger 30 to continue heating.
  • Enter the sixth heat exchanger 31 to heat up to 140 ° C sterilization temperature.
  • After maintaining for 30 seconds enter the seventh heat exchanger 32 for heat recovery, and then enter the eighth heat exchanger 33 and the ninth heat exchanger 34 to cool down to Filled at 25 ° C in an aseptic filling machine 17.
  • the hot water corresponding to the heat exchange of the material is provided by the hot water tank 6.
  • the hot water first passes through the seventh heat exchanger 32 and the 140 ° C high-temperature material for a heat recovery, then rises from about 50 ° C to more than 100 ° C, and then is divided into Two ways, the first way directly enters the second steam heat exchanger 37 and heats up to 144 ° C (the first sterilization temperature) and then enters the tenth heat exchanger 35, and the second way enters the tenth heat exchanger 35 to the first heat exchanger 35.
  • the temperature is adjusted all the way, so that the high-temperature hot water output from the tenth heat exchanger 35 which is about to enter the sixth heat exchanger 31 is within 3 ° C higher than the temperature of the material output from the sixth heat exchanger 31.
  • the first set temperature is controlled by the material hot water temperature adjustment proportional adjustment valve 7. With this setting, it is possible to prevent the material from scaling when the temperature rises due to the large temperature difference.
  • the first set temperature is also 143 ° C, and the outlet temperature of the material in the sixth heat exchanger 31 is 140 ° C.
  • the temperature proportional control valve 7 performs recycling adjustment to control the amount of heat recovery to achieve material cooling; after the heat exchange, the high-temperature hot water can exchange heat to the back-end low-temperature materials and finally can be cooled to about 50 ° C to 60 ° C and returned to the hot water.
  • Tank 6 After the first circuit and the second steam heat exchanger 37 exchange heat, the temperature is raised to 144 ° C., and then the temperature is maintained for 30 seconds, and sterilization is performed to obtain sterile high-temperature hot water.
  • the SIP / shielded steam inlet valve 21 and the SIP / shielded steam outlet valve 23 are closed to stop the steam shielding of the first pipeline 25, and at the same time, the steam condensate quick-release valve 22 is opened to protect the external condensate discharge pipeline with steam shielding.
  • the shielding temperature detector 11 can be used to detect that the shielding temperature reaches 125 ° C. When the detection value of the shielding temperature detector 11 is lower than 2 ° C below the shielding temperature of 125 ° C, the steam SIP discharge valve 12 is opened again for fast exhaust heating to the shielding. When the detection value of the temperature detector 11 returns to above 125 ° C, it is closed to continue the heat preservation and maintain the external shielding state.
  • the aseptic water aseptic T-shaped diaphragm valve 10 and the aseptic hot water aseptic T-shaped diaphragm valve 19 can be opened.
  • the aseptic The back pressure of the hot water supply constant pressure valve 18 is less than the back pressure of the material hot water system constant pressure valve 20, but it must be greater than the back pressure of the sterile water cooling system constant pressure valve 24.
  • a pipe 25 flows to the sterile water side of the low-pressure side, passes through the sterile water sterile T-shaped diaphragm valve 10, and then enters the first heat exchanger 26 for heat exchange and mixing, and then is cooled to 50 by the third heat exchanger 28 After °C, the aseptic filling machine 17 will be supplied together; as the first pipeline 25 gradually fills the aseptic high-temperature hot water into the aseptic water circulation system, the aseptic water circulation system in the aseptic water circulation system is gradually reduced. Flow rate, and at the same time, add pure water at room temperature to the high-temperature hot water circulation system.
  • the amount of heat exchange steam used for heating and sterilization will also decrease, which effectively reduces the energy consumption indicators of steam, ice water, and tower water during the operation of the aseptic water circulation system.
  • the cost of operation is greatly reduced.
  • the high-temperature hot water circulating in the water circulation system will also be reduced.
  • purified water at normal temperature it is directly used for heat recovery and heat exchange with high-temperature materials in the material circulation system. If it is lower than the temperature of the high-temperature hot water under normal reflux, the heat recovery and cooling capacity of the material will be better, and the material temperature can be lowered, which can effectively reduce the energy consumption of the cooling tower and ice water.

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  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Veterinary Medicine (AREA)
  • Epidemiology (AREA)
  • Public Health (AREA)
  • General Health & Medical Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • Chemical & Material Sciences (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Apparatus For Disinfection Or Sterilisation (AREA)
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  • Heat Treatment Of Water, Waste Water Or Sewage (AREA)

Abstract

一种用于无菌灌装生产线的杀菌工艺，在高温热水循环系统和无菌水循环系统之间设置第一管路（25）；分别对物料循环系统、高温热水循环系统、无菌水循环系统、第一管路（25）进行预清洗，之后运行各个系统并连通第一管路（25）；在高温热水循环系统中，当高温热水升温至第一杀菌温度后，保温第一时间段对高温热水进行杀菌以得到无菌的高温热水；随着第一管路（25）逐渐将无菌的高温热水补充进无菌水循环系统中，逐渐减小无菌水循环系统中自供应的无菌水的流量，同时向高温热水循环系统中补充常温的纯净水。

Description

一种用于无菌灌装生产线的杀菌工艺 技术领域
本发明涉及一种用于无菌灌装生产线的杀菌工艺。
背景技术
在无菌灌装生产线上，物料杀菌机和无菌水杀菌机是必不可少的配套设备，必需同时运行为无菌灌装机提供相应处理介质。
物料杀菌机用于产品物料138～140℃超高温瞬时灭菌处理，能有效的杀灭物料中的大肠杆菌、霉菌、致病菌等，同时破坏其中可生长的微生物和芽孢，使灌装后的最终产品能达到长时间运输和储存目的，延长了饮料产品货的架期。而无菌水杀菌机则用于无菌灌装生产中，对饮料包装用的瓶和盖在消毒液消毒过后，再用无菌水进行冲洗，保证产品灌装封盖前所使用到的包材中的残留物冲洗干净无任何残留，而无菌水的生成也是采用超高温瞬时灭菌设备对进入灌装环境的水进行140℃彻底杀菌处理。
而给予物料杀菌机140℃杀菌换热的媒介就是高温热水，其需求高温段的升温温度高达143～145℃，则要高于普通无菌水杀菌机140℃杀菌温度，已完全可以达到无菌水灭菌工艺要求。而物料杀菌机热水系统内管路为带压全封闭结构，完全满足无菌工艺条件。
在物料杀菌机中，与物料换热后的高温热水的最终温度在50-60℃之间，该高温热水回流后用于为物料降温；而在无菌水杀菌机中，无菌水的使用温度为50℃。50-60℃的高温热水对物料的降温效果较差，而将大量的纯净水升温至杀菌温度后再降温至使用温度使用，对纯净水和能源的消耗均较大。
发明内容
本发明的目的是提供一种用于无菌灌装生产线的杀菌工艺，将高 温热水循环系统中生成的高温热水进行保温杀菌处理后，直接转换为无菌水供应使用，在为物料降温后通过第一管路通入无菌水循环系统中。同时逐渐减小无菌水循环系统中自供应的无菌水的流量，而在无菌水循环系统中，随着产能逐渐减小，升温杀菌所使用到的换热蒸汽量也会减少，有效的降低无菌水循环系统在运行时蒸汽、冰水、塔水的能耗指标，从而大大降低运行投入成本，只要无菌水循环系统能一直保证小流量正常运行，保证无菌环境不被破坏，无菌水自身流量缩减得越小，整体运行能耗就越低；而同时高温热水循环系统中循环的高温热水也将减少，通过向高温热水循环系统中补充常温的纯净水，直接用于和物料循环系统中的高温物料进行热回收换热，新补充的常温纯净水要低于正常回流的高温热水的温度，对物料热回收降温能力将更好，可将物料温度降得更低，可有效的降低物料降温后端塔水、冰水等媒介的能耗。
为达到上述目的，本发明采用的技术方案是：
一种用于无菌灌装生产线的杀菌工艺，包括以下步骤：
(1)在高温热水循环系统和无菌水循环系统之间设置第一管路，通过所述第一管路将与物料换热后的高温热水部分输送至所述无菌水循环系统中；
(2)分别对物料循环系统、所述高温热水循环系统、所述无菌水循环系统、所述第一管路进行预清洗，清洗合格后运行所述物料循环系统、所述高温热水循环系统、所述无菌水循环系统，并连通所述第一管路；
(3)在所述高温热水循环系统中，当高温热水升温至第一杀菌温度后，保温第一时间段对高温热水进行杀菌以得到无菌的高温热水；
(4)随着所述第一管路逐渐将无菌的高温热水补充进所述无菌水循环系统中，逐渐减小所述无菌水循环系统中自供应的无菌水的流量，同时向所述高温热水循环系统中补充常温的纯净水。
优选地，在步骤(2)中，向所述无菌水循环系统中补充纯净水，使纯净水在所述无菌水循环系统中循环升温至第二杀菌温度。
优选地，在步骤(2)中，分别隔断所述第一管路与所述高温热水循环系统和所述无菌水循环系统之间的连通状态，接着向所述第一管路中通入具有所述第二杀菌温度的高温水蒸汽，直至所述第一管路中的高温水蒸汽以第一温度保温第二时间段。
优选地，在步骤(2)中，向所述物料循环系统中补充纯净水，并向所述高温热水循环系统中也补充纯净水，使纯净水分别在所述物料循环系统和所述高温热水循环系统中循环升温至所述第二杀菌温度。
优选地，在所述高温热水循环系统中，在高温热水与蒸汽换热之前，将其分成两路，第一路直接与蒸汽换热，第二路先与与蒸汽换热后的所述第一路换热，再回流后汇入与蒸汽换热前的所述第一路，所述第一路与所述第二路换热后与物料换热，所述第一路与物料换热时的温度为第一设定温度。
更优选地，所述第一路与蒸汽换热后，升温至所述第一杀菌温度，并保温所述第一时间段。
更优选地，使所述第一设定温度比与所述第一路换热的物料的温度高出3℃以内。
优选地，在所述高温热水循环系统中，与物料换热后的高温热水通过所述第一管路进入所述无菌水循环系统，并在降温后使用。
优选地，在步骤(4)中，补充的常温纯净水与高温热水混合后直接与物料换热，对物料降温。
由于上述技术方案的运用，本发明与现有技术相比具有下列优点：本发明一种用于无菌灌装生产线的杀菌工艺，将高温热水循环系统中生成的高温热水进行保温杀菌处理后，直接转换为无菌水供应使用，在为物料降温后通过第一管路通入无菌水循环系统中。同时逐渐减小 无菌水循环系统中自供应的无菌水的流量，而在无菌水循环系统中，随着产能逐渐减小，升温杀菌所使用到的换热蒸汽量也会减少，有效的降低无菌水循环系统在运行时蒸汽、冰水、塔水的能耗指标，从而大大降低运行投入成本，只要无菌水循环系统能一直保证小流量正常运行，保证无菌环境不被破坏，无菌水自身流量缩减得越小，整体运行能耗就越低；而同时高温热水循环系统中循环的高温热水也将减少，通过向高温热水循环系统中补充常温的纯净水，直接用于和物料循环系统中的高温物料进行热回收换热，新补充的常温纯净水要低于正常回流的高温热水的温度，对物料热回收降温能力将更好，可将物料温度降得更低，可有效的降低物料降温后端塔水、冰水等媒介的能耗。
附图说明
附图1为应用本发明工艺的无菌灌装生产线的结构示意图。
其中：1、物料回流切罐阀；2、物料平衡罐；3、物料出口切罐阀；4、物料SIP罐；5、脱气均质机；6、热水罐；7、物料热水调温比例调节阀；8、无菌水杀菌温度检测仪；9、无菌水杀菌温度比例阀；10、无菌水无菌T型隔膜阀；11、屏蔽温度检测仪；12、蒸汽SIP排放阀；13、无菌水SIP罐；14、无菌水出口切罐阀；15、无菌水平衡罐；16、无菌水回流切罐阀；17、无菌灌装机；18、无菌热水供应恒压阀；19、无菌热水无菌T型隔膜阀；20、物料热水系统恒压阀；21、SIP/屏蔽蒸汽进口阀；22、蒸汽冷凝水快排阀；23、SIP/屏蔽蒸汽出口阀；24、无菌水降温系统恒压阀；25、第一管路；26、第一换热器；27、第二换热器；28、第三换热器；29、第四换热器；30、第五换热器；31、第六换热器；32、第七换热器；33、第八换热器；34、第九换热器；35、第十换热器；36、第一蒸汽换热器；37、第二蒸汽换热器。
具体实施方式
下面结合附图来对本发明的技术方案作进一步的阐述。
参见图1所示，为结合物料杀菌机和无菌水杀菌机的一体机，在高温热水循环系统和无菌水循环系统之间添加了第一管路25。
工作前：
首先对无菌水循环系统进行SIP清洗，供水由无菌水SIP罐13提供，无菌水依次经过第一换热器26、第二换热器27、第一蒸汽换热器36、再回流经过第二换热器27、第一换热器26、第三换热器28、无菌灌装机17后回流至无菌水SIP罐13中。第一换热器26和第二换热器27用于使壳程和管程中的无菌水相互换热，第一蒸汽换热器36用于将无菌水循环系统中的无菌水循环升温至第二杀菌温度，保温30min。在本实施例中，第二杀菌温度为143℃。
接着对第一管路25进行SIP清洗，介质为143℃(第二杀菌温度)的高温水蒸汽，蒸汽SIP启动时，蒸汽冷凝水快排阀22和蒸汽SIP排放阀12都打开，快速的排放蒸汽冷凝水，冷凝水排放结束后，蒸汽冷凝水快排阀22单独关闭，同时SIP/屏蔽蒸汽进口阀21打开，SIP高温纯蒸汽进入整个第一管路25中，143℃高温蒸汽经过无菌热水供应调节阀后，通过SIP/屏蔽蒸汽出口阀23打开，再进入蒸汽SIP排放阀12进行快速排放，当屏蔽温度检测仪11检测杀菌温度为138℃(第一温度)达标合格后，蒸汽SIP排放阀12单独关闭，进行蒸汽保温杀菌计时30分钟(第二时间段)；当保温杀菌过程中屏蔽温度检测仪11检测杀菌温度低于杀菌计时温度138℃的温度2℃以下时，蒸汽SIP排放阀12再次打开进行快排升温，至回温后重新进入30分钟计时状态；在整个第一管路25蒸汽杀菌过程中，下端的无菌水无菌T型隔膜阀10、上端的无菌热水无菌T型隔膜阀19都处于关闭状态；而整个第一管路25蒸汽杀菌结束后，高温纯蒸汽还是需要通入，使用纯蒸汽进行屏蔽保护，保证上下管路始终处于无菌状态，此时无菌热水无菌T型隔膜阀19阀腔中还未开始SIP杀菌正处于有菌状态。
然后同时对物料循环系统、高温热水循环系统进行SIP清洗，供水分别由物料SIP罐4和热水罐6提供，物料SIP罐4中的无菌水依次经过第四换热器29、脱气均质机5、第五换热器30、第六换热器 31升温，再经过第七换热器32、第八换热器33、第九换热器34降温，再经过无菌灌装机17后回流至物料SIP罐4中；热水罐6中的无菌水依次经过第七换热器32、第二蒸汽换热器37升温，再经过第十换热器35调节第一设定温度，再依次经过第六换热器31、第五换热器30、第四换热器29降温，最后回流至热水罐6中。第二蒸汽换热器37用于将物料循环系统以及高温热水循环系统中的无菌水循环升温至143℃(第二杀菌温度)，保温30min。
工作时：
首先无菌水侧处于正常供应状态，此时无菌水出口切罐阀14关闭，系统供水由无菌水平衡罐15供应，同时无菌水回流切罐阀16关闭，将回流同时切回到无菌水平衡罐15中，整个系统生成回路。通过无菌水杀菌温度检测仪8设置SIP杀菌温度140℃，通过调节无菌水杀菌温度比例阀9的大小开度控制换热蒸汽量，调整杀菌温度，杀菌后再降温至50℃，不间断供应给无菌灌装机17使用；而整个第一管路25则处于使用纯蒸汽进行125℃以上温度屏蔽的状态。
接着物料侧物料出口切罐阀3关闭，系统供料由物料平衡罐2提供，同时物料回流切罐阀1关闭，将回流同时切回到物料平衡罐2中，整个系统生成回路。物料杀菌生产启动，物料进入物料平衡罐2缓冲，再通过物料脱气换热器升温至75℃进入脱气均质机5中处理后，回到第五换热器30中继续升温后，再进入第六换热器31中升温至140℃杀菌温度，保持30s杀菌后，进入第七换热器32进行热能回收，然后再进入第八换热器33、第九换热器34降温冷却至25℃去无菌灌装机17进行灌装。
而对应物料换热的热水则通过热水罐6提供，热水首先经过第七换热器32与140℃高温物料进行一次热回收后，从50℃左右升温至100℃以上，然后分为两路，第一路直接进入第二蒸汽换热器37中升温至144℃(第一杀菌温度)再进入第十换热器35中，第二路则进入第十换热器35中对第一路进行温度调节，使从第十换热器35中输出的即将进入第六换热器31中的高温热水比第六换热器31输出的物 料的温度高出3℃以内。具体的通过物料热水调温比例调节阀7，来控制该第一设定温度。通过这个设置，能够防止物料在升温时由于温差过大而结垢。在本实施例中，第一设定温度也为143℃，而第六换热器31中，物料的出口温度为140℃。由于酸性物料杀菌温度需要在125-140℃杀菌温度下调节，要保证高温热水143℃杀菌工艺下做到无菌，还得满足不同温度下的物料杀菌目的，只能通过此物料热水调温比例调节阀7进行回收调节，控制热回收量大小来实现物料降温；换热后的高温热水再给后端低温物料进行换热最终可降温至50℃-60℃左右并回流至热水罐6。第一路与第二蒸汽换热器37换热后升温至144℃之后，保温30s，进行杀菌得到无菌的高温热水。
当上述无菌水侧和物料侧都处于正常生产给予无菌灌装机17正常供应状态时，就可以启动物料无菌热水供应。
SIP/屏蔽蒸汽进口阀21、SIP/屏蔽蒸汽出口阀23都关闭，停止对第一管路25的蒸汽屏蔽，同时蒸汽冷凝水快排阀22打开，对外部冷凝水排放管路进行蒸汽屏蔽保护，通过屏蔽温度检测仪11检测屏蔽温度达到125℃即可，当屏蔽温度检测仪11检测值低于屏蔽温度125℃的2℃以下时，蒸汽SIP排放阀12再次打开进行快排升温，至屏蔽温度检测仪11检测值回温到125℃以上时关闭继续保温保持外部屏蔽状态。
此时上下端的无菌水无菌T型隔膜阀10、无菌热水无菌T型隔膜阀19都可以打开，通过设置物料热水系统恒压阀20背压压力为最大，再设置无菌热水供应恒压阀18背压压力小于物料热水系统恒压阀20背压压力，而必须大于无菌水降温系统恒压阀24背压压力，这样高压端的无菌高温热水就通过第一管路25，流向低压端无菌水侧，通过无菌水无菌T型隔膜阀10后再进入第一换热器26进行换热混合后，再经过第三换热器28降温至50℃后一起供应无菌灌装机17使用；随着第一管路25逐渐将无菌的高温热水补充进无菌水循环系统中，逐渐减小无菌水循环系统中自供应的无菌水的流量，同时向高温热水循环系统中补充常温的纯净水。
在无菌水循环系统中，随着产能逐渐减小，升温杀菌所使用到的换热蒸汽量也会减少，有效的降低无菌水循环系统在运行时蒸汽、冰水、塔水的能耗指标，从而大大降低运行投入成本，只要无菌水循环系统能一直保证小流量正常运行，保证无菌环境不被破坏，无菌水自身流量缩减得越小，整体运行能耗就越低；而同时高温热水循环系统中循环的高温热水也将减少，通过向高温热水循环系统中补充常温的纯净水，直接用于和物料循环系统中的高温物料进行热回收换热，新补充的常温纯净水要低于正常回流的高温热水的温度，对物料热回收降温能力将更好，可将物料温度降得更低，可有效的降低物料降温后端塔水、冰水等媒介的能耗。
上述实施例只为说明本发明的技术构思及特点，其目的在于让熟悉此项技术的人士能够了解本发明的内容并加以实施，并不能以此限制本发明的保护范围，凡根据本发明精神实质所作的等效变化或修饰，都应涵盖在本发明的保护范围内。

Claims (9)

  1. 一种用于无菌灌装生产线的杀菌工艺，其特征在于：包括以下步骤：
    (1)在高温热水循环系统和无菌水循环系统之间设置第一管路，通过所述第一管路将与物料换热后的高温热水部分输送至所述无菌水循环系统中；
    (2)分别对物料循环系统、所述高温热水循环系统、所述无菌水循环系统、所述第一管路进行预清洗，清洗合格后运行所述物料循环系统、所述高温热水循环系统、所述无菌水循环系统，并连通所述第一管路；
    (3)在所述高温热水循环系统中，当高温热水升温至第一杀菌温度后，保温第一时间段对高温热水进行杀菌以得到无菌的高温热水；
    (4)随着所述第一管路逐渐将无菌的高温热水补充进所述无菌水循环系统中，逐渐减小所述无菌水循环系统中自供应的无菌水的流量，同时向所述高温热水循环系统中补充常温的纯净水。
  2. 根据权利要求1所述的一种用于无菌灌装生产线的杀菌工艺，其特征在于：在步骤(2)中，向所述无菌水循环系统中补充纯净水，使纯净水在所述无菌水循环系统中循环升温至第二杀菌温度。
  3. 根据权利要求1所述的一种用于无菌灌装生产线的杀菌工艺，其特征在于：在步骤(2)中，分别隔断所述第一管路与所述高温热水循环系统和所述无菌水循环系统之间的连通状态，接着向所述第一管路中通入具有所述第二杀菌温度的高温水蒸汽，直至所述第一管路中的高温水蒸汽以第一温度保温第二时间段。
  4. 根据权利要求1所述的一种用于无菌灌装生产线的杀菌工艺，其特征在于：在步骤(2)中，向所述物料循环系统中补充纯净水，并向所述高温热水循环系统中也补充纯净水，使纯净水分别在所述物料循环系统和所述高温热水循环系统中循环升温至所述第二杀菌温度。
  5. 根据权利要求1所述的一种用于无菌灌装生产线的杀菌工艺，其特征在于：在所述高温热水循环系统中，在高温热水与蒸汽换热之前，将其分成两路，第一路直接与蒸汽换热，第二路先与与蒸汽换热后的所述第一路换热，再回流后汇入与蒸汽换热前的所述第一路，所述第一路与所述第二路换热后与物料换热，所述第一路与物料换热时的温度为第一设定温度。
  6. 根据权利要求5所述的一种用于无菌灌装生产线的杀菌工艺，其特征在于：所述第一路与蒸汽换热后，升温至所述第一杀菌温度，并保温所述第一时间段。
  7. 根据权利要求5所述的一种用于无菌灌装生产线的杀菌工艺，其特征在于：使所述第一设定温度比与所述第一路换热的物料的温度高出3℃以内。
  8. 根据权利要求1所述的一种用于无菌灌装生产线的杀菌工艺，其特征在于：在所述高温热水循环系统中，与物料换热后的高温热水通过所述第一管路进入所述无菌水循环系统，并在降温后使用。
  9. 根据权利要求1所述的一种用于无菌灌装生产线的杀菌工艺，其特征在于：在步骤(4)中，补充的常温纯净水与高温热水混合后直接与物料换热，对物料降温。
PCT/CN2019/087199 2018-09-25 2019-05-16 一种用于无菌灌装生产线的杀菌工艺 WO2020062889A1 (zh)

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