(12) United States Patent
`Taggart
`
`111111
`
`1111111111111111111111111111111111111111111111111111111111111
`US006536188Bl
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 6,536,188 Bl
`Mar.25,2003
`
`(54) METHOD AND APPARATUS FOR ASEPTIC
`PACKAGING
`
`(75)
`
`Inventor: Thomas D. Taggart, South Wales, NY
`(US)
`
`(73) Assignee: Steuben Foods, Inc., Elma, NY (US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 205 days.
`
`(21) Appl. No.: 09/306,552
`
`(22) Filed:
`
`May 6, 1999
`
`Related U.S. Application Data
`(60) Provisional application No. 60/118,404, filed on Feb. 2,
`1999.
`Int. Cl? ................................................ B65B 55/02
`(51)
`(52) U.S. Cl. ............................... 53/425; 53/426; 53!79;
`141/1; 141/4; 422/24; 422/29
`(58) Field of Search .......................... 53/426, 425, 403,
`53/405, 79; 141/1, 4, 64, 236; 422/29, 24,
`302, 28, 292
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`2,380,984 A
`2,491,015 A
`3,783,581 A
`3,891,779 A
`4,045,945 A
`4,175,140 A
`4,369,898 A
`4,370,305 A *
`4,494,357 A
`4,566,591 A
`4,597,242 A
`4,622,800 A
`
`8/1945
`* 12/1949
`1!1974
`6/1975
`9/1977
`11/1979
`1!1983
`1!1983
`1!1985
`1!1986
`7/1986
`11/1986
`
`Moeller
`Poole ... ... ... .. ... ... ... ... .. . 422/28
`Pierce
`Robinson
`Moller eta!.
`Bachmann et a!.
`Andersson
`Affonso ...................... 422/292
`DiGeronimo
`Turtschan et a!.
`Hendriks et a!.
`Turtschan
`
`4,730,482 A
`4,862,933 A *
`4,903,891 A
`4,936,486 A
`4,987,721 A
`4,987,726 A
`4,992,247 A
`4,996,824 A
`5,001,886 A
`5,007,232 A
`5,053,207 A
`5,251,423 A
`5,313,990 A
`5,365,774 A
`5,398,734 A
`5,406,772 A
`5,529,099 A
`5,564,481 A
`5,673,535 A
`5,720,148 A
`5,770,232 A
`5,799,464 A
`5,848,515 A
`5,879,643 A
`6,120,730 A
`
`3/1988
`9/1989
`2/1990
`6/1990
`1!1991
`1!1991
`2/1991
`3/1991
`3/1991
`4/1991
`* 10/1991
`* 10/1993
`5/1994
`11/1994
`3/1995
`4/1995
`6/1996
`10/1996
`10/1997
`2/1998
`* 6/1998
`* 9/1998
`12/1998
`* 3/1999
`* 9/2000
`
`Cerny eta!.
`Gies .. ... ... ... ... ... .. ... ... ... 53/426
`Gordon
`Kummerer
`Turtschan
`Petho eta!.
`Foti
`Torterotot
`Turtschan
`Caudill
`Lervick ...................... 422/292
`Turtschan ... ... ... .. ... ... ... 53/426
`Clusserath
`Horlacher
`Hartel
`Dinius
`Janek eta!.
`Clusserath
`Jagger
`Bedin eta!.
`................. 424/616
`Sizer et a!.
`Olsson . ... ... ... ... .. ... ... ... 53/425
`Catelli eta!.
`Katschnig et a!. .......... 422/302
`Palaniappan et a!. ......... 422/28
`
`FOREIGN PATENT DOCUMENTS
`
`5/1998
`6/1996
`
`EP
`0 569 754 B1
`96-8699
`KR
`* cited by examiner
`Primary Examiner--Eugene Kim
`Assistant Examiner---Sameh Tawfik
`(74) Attorney, Agent, or Firm---Schmeiser, Olsen & Watts
`
`(57)
`
`ABSTRACT
`
`A method and apparatus for providing aseptically processed
`low acid products in a container having a small opening,
`such as a glass or plastic bottle or jar, at a high output
`processing speed.
`
`20 Claims, 14 Drawing Sheets
`
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`p. E1
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`U.S. Patent
`
`Mar.25,2003
`
`Sheet 1 of 14
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`U.S. Patent
`US. Patent
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`Mar.25,2003
`Mar. 25, 2003
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`U.S. Patent
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`Mar.25,2003
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`U.S. Patent
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`Mar.25,2003
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`Sheet 5 of 14
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`U.S. Patent
`US. Patent
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`Mar.25,2003
`Mar. 25, 2003
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`Sheet 6 0f 14
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`U.S. Patent
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`Mar.25,2003
`Mar. 25, 2003
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`Sheet 7 of 14
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`US 6,536,188 Bl
`US 6,536,188 B1
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`U.S. Patent
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`Mar.25,2003
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`Sheet 8 of 14
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`U.S. Patent
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`Mar.25,2003
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`U.S. Patent
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`Mar. 25, 2003
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`Sheet 10 of 14
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`U.S. Patent
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`Mar. 25, 2003
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`Sheet 12 of 14
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`U.S. Patent
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`Mar.25,2003
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`Sheet 13 of 14
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`US 6,536,188 Bl
`
`1
`METHOD AND APPARATUS FOR ASEPTIC
`PACKAGING
`
`This application claims the benefit of Provisional Appli(cid:173)
`cation No. 60/118,404, filed Feb. 2, 1999.
`
`FIELD OF THE INVENTION
`
`The present invention relates generally to systems for the
`aseptic packaging of food products. More particularly, the
`present invention relates to an aseptic packaging system for
`the aseptic packaging of food products in containers such as
`bottles or jars.
`
`20
`
`BACKGROUND OF THE INVENTION
`Sterilized packaging systems in which a sterile food 15
`product is placed and sealed in a container to preserve the
`product for later use are well known in the art. Methods of
`sterilizing incoming containers, filling the containers with
`pasteurized product, and sealing the containers in an aseptic
`tunnel are also known.
`Packaged food products can generally be categorized as
`high acid products (Ph below 4.5) or low acid products (Ph
`of 4.5 and above). The high acid content of a high acid
`product helps to reduce bacteria growth in the product, 25
`thereby increasing the shelf life of the product. The low acid
`content of a low acid product, however, necessitates the use
`of more stringent packaging techniques, and often requires
`refrigeration of the product at the point of sale.
`Several packaging techniques, including extended shelf
`life (ESL) and aseptic packaging, have been developed to
`increase the shelf life of low acid products. During ESL
`packaging, for example, the packaging material is com(cid:173)
`monly sanitized and filled with a product in a presterilized
`tunnel under "ultra-clean" conditions. By using such ESL 35
`packaging techniques, the shelf life of an ESL packaged
`product is commonly extended from about 10 to 15 days to
`about 90 days. Aseptic packaging techniques, however,
`which require that the packaging take place in a sterile
`environment, using presterilized containers, etc., are capable 40
`of providing a packaged product having an even longer shelf
`life of 150 days or more. In fact, with aseptic packaging, the
`shelf life limitation is often determined by the quality of the
`taste of the packaged product, rather than by a limitation
`caused by bacterial growth.
`For the aseptic packaging of food products, an aseptic
`filler must, for example, use an FDA (Food and Drug
`Administration) approved sterilant, meet FDA quality con(cid:173)
`trol standards, use a sterile tunnel or clean room, and must
`aseptically treat all packaging material. The food product
`must also be processed using an "Ultra High Temperature"
`(UH1) pasteurization process to meet FDA aseptic stan(cid:173)
`dards. The packaging material must remain in a sterile
`environment during filling, closure, and sealing operations.
`Many attempts have been made, albeit unsuccessfully, to
`aseptically fill containers, such as bottles or jars having
`small openings, at a high output processing speed. In
`addition, previous attempts for aseptically packaging a low
`acid product in plastic bottles or jars (e.g., formed of
`polyethylene terepthalate (PE1) or high density polyethyl(cid:173)
`ene (HDPE)), at a high output processing speed, have also
`failed. Furthermore, the prior art has not been successful in
`providing a high output aseptic filler that complies with the
`stringent United States FDA standards for labeling a pack(cid:173)
`aged product as "aseptic." In the following description of the
`present invention, the term "aseptic" denotes the United
`States FDA level of aseptic.
`
`5
`
`10
`
`2
`SUMMARY OF THE INVENTION
`In order to overcome the above deficiencies, the present
`invention provides a method and apparatus for providing
`aseptically processed low acid products in a container hav-
`ing a small opening, such as a glass or plastic bottle or jar,
`at a high output processing speed.
`Many features are incorporated into the aseptic processing
`apparatus of the present invention in order to meet the
`various United States FDA aseptic standards and the 3A
`Sanitary Standards and Accepted Practices.
`The aseptic processing apparatus of the present invention
`uses filtered air to maintain a positive pressure within a filler
`apparatus. The filler apparatus includes a sterile tunnel that
`is pressurized to a level greater than atomospheric pressure
`using filtered sterile air. The filler apparatus includes three
`interfaces with the ambient environment, each of which
`eliminates the possibility of external contamination. The
`first interface is where containers first enter the sterile tunnel
`through a bottle infeed and sterilization apparatus. In accor(cid:173)
`dance with the present invention, there is always an outflow
`of aseptic sterilant (e.g., hydrogen peroxide) enriched sterile
`air from the first interface to prevent contaminants from
`entering the sterile tunnel. The second interface with the
`sterile tunnel is the path where incoming lid stock enters a
`lid sealing and heat sealing apparatus. To prevent
`contamination, the lid stock passes through a hydrogen
`peroxide bath that provides an aseptic barrier for any con(cid:173)
`taminants that enter the sterile tunnel through the second
`30 interface. The third interface with the sterile tunnel is at an
`exit opening of a discharge apparatus where sealed contain(cid:173)
`ers leave the sterile tunnel. Positive sterile air pressure
`within the sterile tunnel ensures that sterile air is continu-
`ously flowing out of the exit opening of the discharge
`apparatus, thereby preventing contaminants from entering
`the sterile tunnel through this interface.
`The aseptic processing apparatus includes a conveying
`apparatus for transporting the containers through a plurality
`of processing stations located within the sterile tunnel. The
`entire conveying apparatus is enclosed within the sterile
`tunnel, and is never is exposed to unsterile conditions.
`The interior surface of a container such as a bottle or jar
`is much more difficult to aseptically sterilize than the interior
`surface of a cup. A cup generally has a large opening
`45 compared to its height, whereas a bottle or jar generally has
`a small opening compared to its height and its greatest width
`(e.g., the ratio of the opening diameter to the height of the
`container is less than 1.0). A sterilant can be introduced,
`activated, and removed in a cup much more rapidly than in
`50 a bottle or jar. The processing speed when using a bottle or
`jar is limited, in part, by the time required to aseptically
`sterilize the interior surface of the bottle or jar. The aseptic
`processing apparatus of the present invention overcomes the
`processing speed limitations associated with the use of
`55 containers such as bottles or jars.
`A high output processing speed is achieved in the present
`invention by applying a hot atomized sterilant, such as a
`hydrogen peroxide spray onto the interior surface of each
`container, and by subsequently activating and removing the
`60 sterilant in a plurality of drying stations using hot sterile air.
`For example hydrogen peroxide breaks down into water and
`oxygen, and thus oxidizes and kills bacteria within the
`container. To achieve aseptic sterilization, a minimum con(cid:173)
`tainer temperature is developed and held for a predetermined
`65 period of time (e.g., 131 oF. for 5 seconds) after application
`of the sterilant. Hot sterile air is delivered at a high volume
`and a relatively low temperature to dry the container and to
`
`p. E16
`
`

`

`US 6,536,188 Bl
`
`4
`FIG. 16 is a side view of the aseptic processing apparatus
`indicating the control and monitoring locations that are
`interfaced with a control system.
`
`5
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`35
`
`3
`prevent the container (if formed of plastic) from being
`heated to its softening temperature. After container drying,
`the residual hydrogen peroxide in the container is below a
`predetermined level (e.g., about 0.5 PPM (parts per
`million)).
`The present invention generally provides a method for
`aseptically bottling aseptically sterilized foodstuffs compris(cid:173)
`ing the steps of:
`providing a plurality of bottles;
`aseptically disinfecting the plurality of bottles;
`aseptically filling the aseptically disinfected plurality of
`bottles with the aseptically sterilized foodstuffs; and
`filling the aseptically disinfected plurality of bottles at a
`rate greater than 100 bottles per minute.
`The present invention additionally provides a method for
`aseptically bottling aseptically sterilized foodstuffs compris(cid:173)
`ing the steps of:
`providing a plurality of bottles;
`aseptically disinfecting the bottles at a rate greater than
`100 bottles per minute; and
`aseptically filling the bottles with aseptically sterilized
`foodstuffs.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Although certain preferred embodiments of the present
`invention will be shown and described in detail, it should be
`understood that various changes and modifications may be
`10 made without departing from the scope of the appended
`claims. The scope of the present invention will in no way be
`limited to the number of constituting components, the mate(cid:173)
`rials thereof, the shapes thereof, the relative arrangement
`thereof, etc., and are disclosed simply as an example of the
`15 preferred embodiment. The features and advantages of the
`present invention are illustrated in detail in the accompany(cid:173)
`ing drawings, wherein like reference numerals refer to like
`elements throughout the drawings. Although the drawings
`are intended to illustrate the present invention, the drawings
`20 are not necessarily drawn to scale.
`The present invention provides an aseptic processing
`apparatus 10 that will meet the stringent FDA (Food and
`Drug Administration) requirements and 3A Sanitary Stan-
`25 dards and Accepted Practices required to label a food
`product (foodstuffs) as "aseptic". Hereafter, "aseptic" will
`refer to the FDA level of aseptic. The present invention
`The features of the present invention will best be under(cid:173)
`provides a method and apparatus for producing at least about
`stood from a detailed description of the invention and a
`a 12 log reduction of Clostridium botulinum in food prod-
`preferred embodiment, thereof selected for the purposes of
`30 ucts. In addition, the present invention produces packaging
`illustration, and shown in the accompanying drawings in
`material with at least about a 6 log reduction of spores.
`which:
`Actual testing of the aseptic processing apparatus is accom(cid:173)
`FIG. 1 is a plan view of an aseptic processing apparatus
`plished with spore test organisms. These test organisms are
`in accordance with a preferred embodiment of the present
`selected on their resistance to the media selected used to
`invention;
`achieve sterility. For example, when steam is the media, the
`FIG. 2 is a side view of the aseptic processing apparatus
`test organism is Bacillus stearothermophilus. When hydro(cid:173)
`of FIG. 1;
`gen peroxide is the media, then the test organism is Bacillus
`subtilis var. globigii.
`FIG. 3 is a partial cross-sectional side view of the aseptic
`processing apparatus of FIG. 1;
`The present invention processes containers such as bottles
`FIG. 4 is a cross-sectional side view of a bottle infeed and 40 or jars that have a small opening compared to its height and
`its greatest width (e.g., the ratio of the opening diameter to
`sterilization apparatus;
`the height of the container is less than 1.0). In the preferred
`FIG. 5 illustrates a cross-sectional top view of the bottle
`embodiment, a bottle 12 (see, e.g., FIG. 8) is illustrated as
`infeed and sterilization apparatus taken along line 5-5 of
`the container. The container may alternately comprise a jar.
`FIG. 4;
`The bottle 12 is preferably formed of a plastic such as
`FIG. 6 is an interior sectional view of an interior wall 45
`polyethylene terepthalate (PET) or high density polyethyl(cid:173)
`taken along line 6-6 of FIG. 4;
`ene (HDPE), although other materials such as glass may also
`FIG. 7 is a cross-sectional view of the bottle infeed and
`be used. The present invention uses an aseptic sterilant such
`sterilization apparatus taken along line 7-7 of FIG. 4;
`as hydrogen peroxide (H2 0 2) or oxonia to sterilize the
`FIG. 8 is a perspective view of a conveying plate for use 50 bottles 12. In the preferred embodiment of the present
`invention, hydrogen peroxide is used as the sterilant. The
`in the aseptic processing apparatus of the present invention;
`FIG. 9 is a perspective view of a partition in a sterile
`present invention uses hydrogen peroxide with a concentra-
`tunnel;
`tion of less than about 35% and ensures that the bottles 12
`FIG. 10 is a cross-sectional side view of an interior bottle
`have less than about 0.5 ppm of residual hydrogen peroxide
`sterilization apparatus and the partition located between 55 after each bottle 12 is sterilized.
`FIGS. 1-3 illustrate several views of an aseptic process-
`stations 8 and 9;
`ing apparatus 10 in accordance with a preferred embodiment
`FIG. 11 is a cross-sectional side view of the partition
`of the present invention. As shown, the aseptic processing
`located between stations 22 and 23;.
`apparatus 10 includes a first bottle unscrambler 20, a second
`FIG. 12 is a cross-sectional side view of the partition 60 bottle unscramble 30, and a bottle lifter 40 for providing a
`located between stations 35 and 36;
`supply of properly oriented empty bottles. The empty bottles
`FIG. 13 is a cross-sectional side view of a lid sterilization
`are delivered to a filler apparatus 50 after passing through a
`and heat sealing apparatus;
`bottle infeed and sterilization apparatus 60 for aseptic ster(cid:173)
`FIG. 14 is a side view of a lifting apparatus with a gripper
`ilization. The filled bottles are sealed at a first capping
`mechanism for lifting the bottles from the sterile tunnel;
`65 apparatus 400 or a second capping apparatus 410. A control
`system 550 monitors and controls the operation of the
`FIG. 15 is a top view of the aseptic processing apparatus;
`and
`aseptic processing apparatus 10. The filled and sealed bottles
`
`p. E17
`
`

`

`US 6,536,188 Bl
`
`5
`are packed and palletized using a first case packing appa(cid:173)
`ratus 480, a second case packing apparatus 490, a first
`palletizer 500, and a second palletizer 510.
`The bottles 12 arrive at a first bottle unscrambler 20 with
`a random orientation, such that an opening 16 (see FIG. 8)
`of each bottle 12 can be oriented in any direction. The first
`bottle unscrambler 20 manipulates the bottles 12 until the
`opening 16 of each bottle 12 is in a top vertical position. The
`bottles 12 leave the first bottle unscrambler 20 in a series
`formation with the opening 16 of each bottle 12 oriented
`vertically. The bottles 12 travel in single file in a first lane 18
`to a first bottle lifter 40. The first bottle lifter 40 lifts and
`transports the bottles 12 to a bottle infeed and sterilization
`apparatus 60. A second bottle unscrambler 30 may also used
`to provide a supply of vertically oriented bottles 12. The
`bottles 12 output from the second bottle unscrambler 30
`travel in single file in a second lane 22 to a second bottle
`lifter 42, which lifts and transports the bottles 12 to the bottle
`infeed and sterilization apparatus 60.
`FIG. 3 illustrates the bottle infeed, sterilization, and
`conveying apparatus 60 attached to the filler apparatus 50.
`FIG. 4 illustrates a cross-sectional side view of the bottle
`infeed, sterilization, and conveying apparatus 60. FIG. 5
`illustrates a cross-sectional top view of the bottle infeed,
`sterilization, and conveying apparatus 60 taken along line
`5-5 of FIG. 4. The bottle infeed and sterilization apparatus
`60 preferably inputs six bottles 12 in a horizontal direction
`from the first lane 18 and six bottles in a horizontal direction
`from the second lane 22 (FIG. 5). A gate 76 in the first lane
`18 selectively groups six bottles 12 at a time in first
`horizontal row 24. A gate 78 in the second lane 22 selec(cid:173)
`tively groups six bottles 12 at a time in a second horizontal
`row 28. An infeed apparatus 80 includes a pushing element
`84 for pushing the bottles 12 in the first horizontal row 24
`into a first vertical lane 26. A corresponding infeed apparatus
`80 includes a pushing element 86 for pushing the bottles 12
`in the second horizontal row 28 into a second vertical lane
`32. The six bottles 12 in the first vertical lane 26 and the six
`bottles 12 in the second vertical lane 32 are directed down(cid:173)
`ward into the bottle infeed and sterilization apparatus 60.
`Referring to FIG. 4, as the bottles 12 move downward in
`the first vertical lane 26 and the second vertical lane 32, a
`sterilant 14, such as heated hydrogen peroxide, oxonia, or
`other aseptic sterilant, is applied to an outside surface 34 of
`each bottle 12 by a sterilant application apparatus 36. The
`outside surface 34 of a bottle 12 is illustrated in greater detail
`in FIG. 8. The bottles 12 may move downward in the first
`vertical lane 26 and the second vertical lane 32 by the force
`of gravity. Alternatively, controlled downward movement of
`the bottles 12 can be created by the use of a conveying
`device such as a moving conveying chain. A plurality of pins
`are attached to the conveying chain. Each bottle 12 rests on
`one of the pins attached to the conveying chain. Therefore,
`the motion of each bottle is controlled by the speed of the
`moving conveying chain.
`A sterilant such as hydrogen peroxide may be provided to
`the sterilant application apparatus 36 in many ways. For
`example, liquid hydrogen peroxide may be provided in a
`reservoir at a level maintained by a pump and overflow pipe.
`A plurality of measuring cups (e.g., approximately 0.5 ml
`each) connected by an air cylinder are submerged into the
`reservoir and are lifted above the liquid level. Thus, a
`measured volume of liquid hydrogen peroxide is contained
`in each measuring cup.
`Each measuring cup may include a conductivity probe
`that is configured to send a signal to the control system 550
`
`20
`
`10
`
`6
`indicating that the measuring cup is full. A tube (e.g., having
`a diameter of about 1/16") is positioned in the center of the
`measuring cup. A first end of the tube is positioned near t~e
`bottom of the measuring cup. A second end of the tube 1s
`5 connected to the sterilant application apparatus 36. The
`sterilant application apparatus 36 includes a venturi and a
`heated double tube heat exchanger. When the measuring cup
`is full, and a signal is received from the control system 550,
`a valve is opened allowing pressurized sterile air to enter the
`venturi. The pressurized air flow causes a vacuum to be
`generated in second end of the tube causing liquid hydrogen
`peroxide to be pulled out of the measuring cup. The liquid
`hydrogen peroxide is sprayed into a sterile air stream which
`atomizes the hydrogen peroxide into a spray. The atomized
`15 hydrogen peroxide enters the double tube heat exchanger in
`order to heat the atomized hydrogen peroxide to its vapor(cid:173)
`ization phase. The double tube heat exchanger is heated with
`steam and the temperature is monitored and controlled by
`the control system 550. In FIG. 4, the application of the
`sterilant 14 by the sterilant application apparatus 36 is
`accomplished through the use of spray nozzles 64 that
`produce a sterilant fog which is directed to the outside
`surface 34 of each bottle 12.
`Alternatively, a direct spray of heated hydrogen peroxide
`25 may be continuously applied to the outside surface 34 of
`each bottle 12. For producing the direct spray, a metering
`pump regulates the amount of hydrogen peroxide, a flow
`meter continuously measures and records the quantity of
`hydrogen peroxide being dispensed, a spray nozzle produces
`30 a fine mist, and a heat exchanger heats the hydrogen
`peroxide above the vaporization point.
`FIGS. 3 and 4 illustrate the sterilization chamber 38 for
`activation and drying of bottles 12 which is included in the
`bottle infeed, sterilization, and conveying apparatus 60. The
`35 sterilization chamber 38 sterilizes the outside surface 34 of
`each bottle 12. The sterilization chamber 38 encloses a
`conduit 39. Sterile heated air, which is generated by a sterile
`air supply system 146 (FIG. 3), enters the conduit 39 of the
`sterilization chamber 38 through ports 64 and 68 located at
`40 the bottom of the sterilization chamber 38. The sterile heated
`air also enters through a bottom opening 62 of the bottle
`infeed and sterilization apparatus 60. The sterile heated air
`travels up through the conduit 39 of the sterilization cham(cid:173)
`ber 38, and exits the top of the sterilization chamber 38
`45 through an exhaust conduit 70. The sterile heated air con(cid:173)
`tinuously flows in an upward direction through the steril(cid:173)
`ization chamber 38, thus preventing any contaminants from
`entering the bottle infeed and sterilization apparatus 60. To
`create the sterile heated air, the air is first passed through a
`50 filtering system (e.g., a group of double sterile air filters) to
`sterilize the air. The air is then heated in a heating system
`(e.g., an electric heater) to about 230° F. The air temperature
`is regulated by the control system 550. Other techniques for
`providing the sterile heated air may also be used. The control
`55 system 550 monitors the air pressure and flow rate of the
`sterile heated air to ensure that an adequate flow of the hot
`sterile air is maintained in the bottle sterilization chamber 38
`of the bottle infeed and sterilization apparatus 60.
`As illustrated in FIGS. 4, 6, and 7, the sterilization
`60 chamber 38 includes two opposing, interior, perforated walls
`72A, 72B. The perforated walls 72A and 72B guide the
`bottles 12 downward in the first vertical lane 26 and the
`second vertical lane 32, respectively. The perforated walls
`72A, 72B also allow the complete circulation of hot sterile
`65 air around the outside surface 34 of each bottle 12 in the
`sterilization chamber 38. The sterilization chamber 38 sup(cid:173)
`plies hot sterile air to the outside surface 34 of each bottle
`
`p. E18
`
`

`

`US 6,536,188 Bl
`
`10
`
`8
`7
`12 between the sterilant application apparatus 36 and the
`At station 4, the bottles 12 in the conveying plate 94 enter
`a bottle detection apparatus 112. The bottle detection appa(cid:173)
`bottom opening 62 of the bottle infeed and sterilization
`ratus 112 determines whether all twelve bottles 12 are
`apparatus 60. This sterilant may be hydrogen peroxide or
`actually present and correctly positioned in the conveying
`oxonia (hydrogen peroxide and peroxyacetic acid).
`5 plate 94. Proximity sensors 114 detect the presence and the
`In accordance with the preferred embodiment of the
`alignment of each bottle 12. In the present invention, a bottle
`present invention, twelve drying positions are provided in
`12 with correct alignment is in an upright position with the
`the sterilization chamber 38. Each bottle 12 is exposed to the
`opening 16 of the bottle 12 located in an upward position.
`hot sterile air in the sterilization chamber 38 for about at
`Information regarding the location of any misaligned or
`least 24 seconds. This provides time sufficient time for the
`missing bottles 12 is relayed to the control system 550. The
`hydrogen peroxide sterilant to break down into water and
`control system 550 uses this location information to ensure
`oxygen, to kill any bacteria on the bottles 12, and to
`that, at future stations 92, bottle filling or sealing will not
`evaporate from the outside surface 34 of the bottles 12.
`occur at the locations corresponding to the misaligned or
`An exhaust fan 73 is located at a top of the exhaust
`missing bottles 12.
`conduit 70 to provide an outlet from a sterile tunnel 90, and
`At station 7, as illustrated in FIGS. 3 and 10, the bottles
`to control the sterile air flow rate through the sterilization 15
`12 in the conveying plate 94 enter an interior bottle steril(cid:173)
`chamber 38. The exhaust fan 73 is controlled by the control
`ization apparatus 116. A sterilant, such as hydrogen
`system 550. The control system 550 controls the sterile air
`peroxide, oxonia, or any other suitable aseptic sterilant is
`temperature preferably to about 230° F., and controls the
`applied as a heated vapor fog into the interior 118 of each
`sterile air flow rate through the sterilization chamber 38. The
`20 bottle 12. Preferably, hydrogen peroxide is used as the
`flow rate is preferably about 1800 scfm through the steril(cid:173)
`sterilant in the present invention. The application of sterilant
`ization chamber 38. The bottles 12 leave the sterilization
`is accomplished with the use of a plurality of sterilant
`chamber 38 with a hydrogen peroxide concentration of less
`measuring devices 120 and applicator spray nozzles 122. A
`than 0.5 PPM.
`separate measuring device 120 and applicator spray nozzle
`As shown in FIGS. 3 and 4, a plurality of proximity
`25 122 are used for each of the twelve bottle 12 locations in the
`sensors 71located along the sides of the vertical lanes 26, 32
`conveying plate 94. Each bottle 12 is supplied with the same
`detect any bottle 12 jams that occur within the sterilization
`measured quantity of sterilant, preferably in the form of a
`chamber 38. The proximity sensors 71 transmit an alarm
`hot vapor fog. The measured quantity of sterilant may be
`signal to the control system 550. The bottles 12 leave the
`drawn from a reservoir 124 of sterilant, heated, vaporized,
`bottle infeed and sterilization apparatus 60 through the
`etc., in a manner similar to that described above with regard
`bottom opening 62, and enter the sterile tunnel 90 of the
`to the sterilant application apparatus 36.
`filler apparatus 50.
`The control system 550 monitors and controls a spray
`In the preferred embodiment of the present invention, the
`apparatus 126 that includes the applicator spray nozzles 122.
`filler apparatus 50 includes forty-one (41) index stations 92,
`Each applicator spray nozzle 122 sprays the sterilant into the
`hereafter referred to as "stations." Various index stations 92 35 interior 118 of a corresponding b