United States Patent [19J
`Scholle et al.
`
`[11]
`
`[45]
`
`4,417,607
`Nov. 29, 1983
`
`[54] APPARATUS AND METHOD FOR
`ASEPTICALLY FILLING FLEXIBLE
`CONTAINERS
`Inventors: William R. Scholle, Corona Del Mar;
`William J. Scholle, Irvine; Michael J.
`Gunning, Cerritos, all of Calif.
`Assignee: Scholle Corporation, Irvine, Calif.
`Appl. No.:
`278,344
`May 7, 1981
`
`PCT Filed:
`PCT No.:
`
`PCT/US81/00614
`
`§ 371 Date:
`
`Jun. 29, 1981
`
`Jun. 29, 1981
`§ 102(e) Date:
`PCT Pub. No.: W082/03832
`PCT Pub. Date: Nov. 11, 1982
`Int. CI.J .......................... B65B 3/04; B67C 1/16;
`B67C 3/34
`U.S. Cl ........................................... 141/1; 141/10;
`141/92; 141/114; 141/154; 53/167; 53/389;
`53/426; 134/134
`Field of Search ......................... 53/167, 389, 426;
`134/83, 134, 133; 141/10, 11, 48, 51, 63, 64, 69,
`70, 82, 85, 89, 91, 92, 114, 313-317, 129-191,
`1-9, 12, 350
`
`[75]
`
`[73]
`[21]
`
`[22]
`
`[86]
`
`[87]
`
`[51]
`
`[52]
`
`[58]
`
`[56]
`
`References Cited
`U.S. PATENT DOCUMENTS
`3,828,833 8/1974 Smith .................................... 141/85
`3,913,634 10/1975 Eisenberg ......... : ................... 141/51
`4,120,134 10/1978 Scholle ........................... 141/114 X
`4,208,852 6/1980 Pioch ................................... 141/243
`_Primary Examiner-Houston S. Bell, Jr.
`
`Attorney, Agent, or Firm-Knobbe, Martens, Olson &
`Bear
`ABSTRACT
`[57]
`An apparatus for aseptically filling premanufactured,
`presterilized, flexible containers, connected in a contin(cid:173)
`uous web, includes a chamber with an inlet mouth for
`receiving empty containers seriatim, and an outlet
`mouth for dispensing filled containers seriatim. The
`inlet and outlet mouths have respective seals for sealing
`to the surface of the containers to prevent entry of
`contaminants into the chamber. This chamber is parti(cid:173)
`tioned to form a spraying compartment, adjacent to the
`inlet mouth, and a filling compartment, adjacent to the
`outlet mouth, with a drying compartment therebe(cid:173)
`tween. A sterilizing agent is continuously sprayed, as a
`mist, into the spraying compartment to coat the exterior
`of the containers with the sterilizing agent as they are
`serially advanced through the chamber. This mist also
`provides an aseptic barrier between the inlet mouth and
`the drying compartment. A source of sterile air is input
`to the filling compartment to maintain a positive pres- .
`sure therein, and thus, prevent entry of contaminants.
`This heated sterile air flows from the filling compart(cid:173)
`ment to the drying compartment to dry the containers
`after they have been sprayed. The containers are then
`advanced to the filling compartment where t]Jey are
`filled and dispensed through th.e outlet mouth.
`The length of time the empty containers are exposed to
`the atmosphere, and thus, the amount of contamination
`on the exterior of the containers, may be reduced by
`utilizing the sealed overwrap bag, in which the contain(cid:173)
`ers are presterilized, to form a relatively sterile tunnel
`for feeding the containers to the inlet mouth.
`
`39 Claims, 8 Drawing Figures
`/0
`
`I
`
`.3c
`
`.31
`
`STERILANT
`SUPPLY
`
`p. E1
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`

`

`U.S. Patent Nov. 29, 1983
`
`Sheet 1 of 3
`
`4,417,607
`
`.34
`
`/0
`
`I
`
`.9~
`
`HE.ATED
`-
`STERILANT STERILE AIR
`-SUPPLY
`SUPPLY
`
`p. E2
`
`

`

`U.S. Patent Nov. 29, 1983
`U.S. Patent
`Nov. 29, 1983
`
`Sheet 2 of 3
`Sheet 2 of 3
`
`4,417,607
`4,417,607
`
`..30
`
`
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`~-.5
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`p. E3
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`

`

`U.S. Patent Nov. 29, 1983
`US. Patent
`Nov. 29, 1983
`
`Sheet 3 of 3
`Sheet 3 of 3
`
`4,417,607
`4,417,607
`
`
`
`p. E4
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`

`

`1
`
`4,417,607
`
`APPARATUS AND METHOD FOR ASEPTICALLY
`FILLING FLEXIBLE CONTAINERS
`
`BACKGROUND OF THE INVENTION
`The present inveritio!l relates to at) .apparatus . and
`method for filling flexible containers in an aseptic envi-
`ronment.
`·
`'
`·
`. '
`Flexible bags, comprised of a plastic material, such as 10
`polyethylene, are well suited as containers for fluid
`substances, such as milk, water, fruit juices, wine, and
`chemicals. Typically, a spout is provided, through
`which the container may be filled and the contents may
`be dispensed. The containers may be connected in con- 15
`tinuous web form and fllled· by advancing the web of
`containers seriatim into a filling station, as described in
`U.S. Pat. No. 4,120,134, issued on Oct. 17, 1978'to Wil(cid:173)
`liam R. Scholle; and assigned to Scholle Corporation.
`The specification of that patent provfdes useful informa- 20
`tion helpful in understanding the context in which the
`present invention operates, and .therefore, that patent is
`hereby incorporated herein by reference.'
`The apparatus described in U.S.•Pat. No. 4,120,134
`includes (a) feed means comprising conveyors' for di- 25
`recting the continuous web; formed' by the intercon(cid:173)
`nected containers, from a supply carton onto a platform
`adjacent the filling station; (b) guide members for align(cid:173)
`ing the filling spout of each container as it moves along
`the platform; (c) a mechanism for uncapping, filling, 30
`· and recapping each container at the filling station; and
`(d) means for releasing the filling spouts after each con(cid:173)
`tainer is filled. As described in this patent, the contain(cid:173)
`ers may be advanced either by a mechanically driven
`conveyor or an inclined passive conveyor. The passive 35
`conveyor utilizes the gravitational force of the filled
`containers on an inclined unloading conveyor to pull
`the web of empty interconnected containers behind it.
`Where the contents of the containers are consumable,
`measures must be taken to insure that such contents are
`free from contamination. If, for example, the containers
`are filled with high acid foods, it is necessary that the
`filling be performed under at least sanitary conditions.
`However, where low acid or neutral pH foods, such as 45
`milk, are involved, it is desirable that the filling be per(cid:173)
`formed under aseptic conditions, since this permits such
`foods to have a longer shelf life than would otherwise
`be possible.
`
`SUMMARY OF THE INVENTION
`The present invention provides an apparatus and
`method for filling flexible containers in an aseptic envi(cid:173)
`ronment. This apparatus comprises a tunnel-like, elon(cid:173)
`gated chamber having an entry' port, through which the 55
`empty containers are fed, and a dispensing port,
`through which the filled containers are dispensed. The
`chamber is partitioned into three compartments, includ(cid:173)
`ing a sterilizing compartment, adjacent to the entry
`port, a filling compartment, adjacent to the dispensing 60
`port, and a drying compartment, interposed between
`the filling and sterilizing compartments. In addition, the
`entry and dispensing ports each have a seal, formed of
`elastomeric material with a slit therein, to reduce the
`risk of contaminant migration into the elongated cham- 65
`ber while permitting the containers to pass there(cid:173)
`through. A supply of sterilized air is continuously input
`to the filling compartment to pressurize the entire elon-
`
`2
`gated chambefand provide a flow of sterile air there(cid:173)
`through to prevent eniry of contaminants.
`The present invention utilizes premanufactured· con(cid:173)
`tainers, connected in a continuous web, which have
`5 been prepackaged in a sealed overwrap container and
`presterilized therein. The sealed overwrap container,
`which comprises, for example, a plastic !Jag, is posi(cid:173)
`tioned adjacent to the entry port. However, before
`opening the overwrap, it is preferably to apply a posi(cid:173)
`tive pressure within the overwrap container· by intro(cid:173)
`ducing sterile air therein. This may be accomplished by
`providing a probe, connected to a source of sterilized
`air, which is used to puncture the wall of the overwrap
`and inflate the overwrap container. An opening is then
`formed in the overwrap container, as by slitting with a
`knife, to provide access to one end of the continuous
`web of containers packaged therein. An operator manu(cid:173)
`ally grasps the end of the continuous web, pulls it
`through the ppening, and operably connects it to the
`feed means of the apparatus, for example, by clipping
`the leading edge. of this continuous web to the trailing
`eqge of the . preceding continuous web of containers.
`·While some contaminants may enter the overwrap con(cid:173)
`tainer during 'this operation, it will be recognized that
`the continuous flow of sterile air from the probe
`through the overwrap container tends to reduce such
`contamination. After the continuous web of containers
`has been operably connected to feed through the elon(cid:173)
`gated chamber, the peripheral edges formed by the
`opening in the overwrap are sealed to the mouth of the
`entry port, as by a resilient band. The air supply to the
`overwrap container may then be discontinued, and the
`probe, if desired, may be withdrawn, thereby leaving a
`small aperture in the wall of the overwrap container. It
`will be recognized, however, that, if the probe is with(cid:173)
`drawn, the positive pressure in the elongated chamber
`should be sufficient to provide a sterile air flow to the
`overwrap container, thereby maintaining it at a positive
`pressure and preventing contaminants from entering
`through .such aperture.
`As the continuous web of containers is serially ad(cid:173)
`vanced into the elongated chamber, through the entry
`port, they initially pass through the sterilizing compart(cid:173)
`ment, where· they are coated with a fine, continuous
`mist of hydrogen peroxide. This resterilizes the outside
`of the containers, and thus, removes any contamination
`that may have occurred during the period when the
`overwrap container was open to the atmosphere. It will
`be understood that the inside of the containers need not
`50 be resterilized, since the containers are sealed with caps
`on their respective spouts, thereby preventing contami(cid:173)
`nation.
`As the containers are further advanced seriatim
`through the elongated chamber, they pass from the
`sterilizing compartment to the drying compartment,
`where the hydrogen peroxide coating is evaporated by
`a flow of heated, sterile air. Further serial advancement
`of the containers moves them from the drying compart(cid:173)
`ment to the filling compartment where the spout caps
`are removed, the containers filled with a food sub(cid:173)
`stance, and the spout caps replaced. The filled contain-
`ers are then advanced out of the filling compartment
`through the seal in the dispensing compartment, and
`onto the inclined conveyor. A severing bar disconnects
`adjacent filled containers at perforations in the con(cid:173)
`tainer web between adjacent containers, so that the
`containers may be deposited into protective enclosures,
`such as cardboard boxes.
`
`40
`
`p. E5
`
`

`

`4,417,607
`
`3
`At all times during the foregoing process, the filling
`compartment is maintained at a positive pressure, by
`inputting, as discussed above, sterile air therein. This
`sterile air flows from the filling compartment to the
`drying compartment, and thus, also serves to maintain 5
`the drying compartment at a positive pressure. Further,
`the hydrogen peroxide mist in the sterilizing compart(cid:173)
`ment provides an aseptic barrier between the drying
`compartment and the entry port. Thus, the filling com(cid:173)
`partment is constantly maintained in an aseptic condi- 10
`tion as the containers are serially advanced there(cid:173)
`through.
`The present invention, therefore, provides an aseptic
`environment for filling premanufactured, prepackaged,
`and presterilized, flexible containers, connected in con- 15
`tinuous web form.
`
`4
`which forms a dispensing port 22 at the opposite end of
`the chamber 18, as shown in FIGS. 1 and 2. A continu(cid:173)
`ous web of containers 24, having respective spouts 25,
`are fed seriatim into the entry port 20. Container supc
`port rollers 23 (FIG. 2), horizontally mounted between
`the sides of the chamber 18, provide support for the
`containers 24 as they are advanced through the elon(cid:173)
`gated chamber 18 by a passive, inclined conveyor 26, as
`describrd in U.S. Pat. No. 4,120,134, issued on Oct. 17,
`1978, to William R. Scholle, and assigned to Scholle
`Corporation, which patent is hereby incorporated by
`reference. Alternatively, the c'ontainers 24 may be ad(cid:173)
`vanced through the elongated chamber 18 by the me(cid:173)
`chanically driven mechanisms described in U.S. Pat.
`No. 4, 120,134, or in copending patent application Ser.
`No. 245,394 entitled "Container Conveyor For a flexi(cid:173)
`ble Container Filling Machine",. filed Mar. 19, 1981, by
`BRIEF DESCRIPTION OF THE DRAWINGS
`Roger H. Ellert, inventor, which is also hereby incorpo-
`rated herein by reference.
`These and other features of the present invention are
`best understood through reference to the drawings in 20 As shown in FIGS. 1 and 2, a filling nozzle 30, for
`filling the comtainers 24, extends through, and is sealed
`which:
`FIG. 1 is an elevation view of the aseptic filling appa-
`to, the top of the elongated chamber 18, near its dispens-
`ratus of the present invention showing the elongated
`ing end. When a container spout 25 reaches a position
`chamber receiving a continuous web of flexible bags
`beneath this nozzle 30, it is uncapped, filled by the noz-
`through an inlet mouth, and dispensing the containers 25 zle 30, and recapped.
`The nozzle 30 is connected to a flow controller 34,
`through an outlet mouth and onto the inclined con-
`veyor, after the containers have been filled by the filling
`mounted on the frame 12, which dispenses measured
`nozzle;
`amounts of product, such as a food substance, through
`FIG. 2 is a partial perspective view of the sterile
`the spout 25 and into the container 24. After the con-
`chamber of FIG. 1;
`30 tainer spout 25 has been uncapped, and the container 24
`FIG. 3 is a schematic drawing of the elongated cham-
`has been filled by nozzle 30, a vertical post 36 is ad-
`ber of FIG. 1 showing the spraying compartment, dry-
`vanced upward to cause the lower wall of the container
`24 to seal off the container spout 25 prior to capping to
`ing compartment, and filling compartment;
`FIG .. 4 is a fragmentary, perspective view of the
`prevent entry of air into the filled container 24. Further
`elongated chamber of FIG. 1, showing the configura- 35 details of this filling mechanism, as well as a capping
`tion of the partition between the spraying compartment
`mechanism for uncapping and recapping the spouts 25,
`and drying compartment, and the configuration of the
`are provided in the above-referenced U.S. Pat. No.
`partition between the drying compartment and filling
`4, 120,134.
`compartment; and further showing the tube which pro-
`After filling, the containers 24 are advanced through
`vides a drain for sterilant condensate and a vent for the 40 the dispensing port 22 and onto the inclined conveyor
`sterile air flow through the elongated chamber;
`26. This inclined conveyor 26 comprises plural idle
`FIG. 5 is a fragmentary perspective view of the con-
`rollers 40 connected between opposing side frames
`tainers being received into the chamber through the
`42,44. The side frames 42,44 are rotatably connected at
`inlet mouth, showing the elastomeric seal sealing to the
`one end to respective brackets 46 connected to a cross
`exterior of the containers;
`45 member 16 of the support frame 12. The brackets 46 are
`FIG. 6 is a fragmentary, perspective view of the filled
`positioned to permit the conveyor 26 to receive filled
`containers being dispensed through the outlet mouth,
`containers 24 from the dispensing port 22. The end of
`showing the elastomeric ·seals sealing to the exterior of
`the inclined conveyor opposite the dispensing port 22 is
`the filled containers;
`supported by a post 50, which may be telescoping~y
`FIG. 7 is a series of perspective views illustrating a 50 adjusted to vary the angle of inclination of the inclined
`method of packaging the continuous web of containers
`conveyor 26. A container separator 52 having a sever-
`for sterilization; and
`ing bar 54 is connected to the side frames of the con-
`FIG. 8 is a series of perspective view illustrating a
`veyor 26. This separator 52 serves to disconnect adja-
`method of opening the container overwrap bag to re-
`cent filled containers 24 at perforations, preformed in
`duce contaminant entry through the opening, and 55 the container web between adjacent containers 24, so
`showing a method of sealing this bag opening to the
`that the containers 24 may be deposited into protective
`inlet mouth of the chamber to form a relatively sterile
`enclosures, such as cardboard boxes.
`tunnel for the containers.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENT
`Referring to FIG. 1, the aseptic filling apparatus 10 of
`the present invention includes a skeletal support frame
`12 formed by plural upstanding posts 14 interconnected
`by plural cross members 16.
`The support frame 12 mounts an elongated chamber
`18, having an inlet mouth 19, which forms an entry port
`20 at one end of the chamber 18, and an outlet mouth 21,
`
`THE CHAMBER 18
`60 As best seen in FIG. 3, the elongated chamber 18 is
`divided into a filling compartment 68, a spraying com(cid:173)
`partment 70, and a drying compartment 72. These com(cid:173)
`partments 68,70,72 are formed by partitions 60,62, ori(cid:173)
`ented perpendicularly to the longitudinal axis of the
`65 chamber 18. The filling compartment 68 is bounded by
`the outlet mouth 21 on one end and the partition 60 on
`the other end. The filling nozzle 30 projects into this
`compartment 68. Further, the spraying compartment is
`
`p. E6
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`

`

`5
`bounded by the inlet mouth 19 and the partition 62,
`while the drying compartment is bounded by the parti(cid:173)
`tions 60,62.
`An elastomeric seal 64 is provided across the inlet
`mouth 19 to seal the entry port 20. The outlet mouth 21 5
`is provided with two elastomeric seals 66,67, in spaced,
`parallel relationship, to form a double seal across the
`dispensing port 22. The partitions 60,62, and seals
`64,66,67, all have opening, described in detail below, to
`permit passage of the continuous web of containers 24 10
`through the chamber 18.
`Referring again to FIGS. 1 and 2, a source of sterile,
`heated air 76 is connected by tubing (not shown) to an
`inlet tube 78 in the filling compartment 68 (FIG. 3) of
`the elongated chamber 18. The chamber 18 also has 15
`plural spray heads 80,82,84,86 connected thereto, which
`are positioned to spray the compartments 70,72,68, and
`mouth 21, respectively. Each of these spray heads
`80,82,84,86 is connected by tubing (not shown) to the
`sterile air supply 76 and to a sterilant supply 88 contain- 20
`ing, for example, a 30-percent solution of hydrogen
`peroxide in water. The spray heads 80,82,84,86 atomize
`the hydrogen peroxide solution into a fine mist or fog,
`and spray such mist into the spraying compartment 70,
`drying compartment 72, filling compartment 68, and 25
`dispensing mouth 21, respectively.
`
`STERILIZING THE CHAMBER 18
`Prior to utilizing the aseptic filling apparatus 10 of the
`present invention, the elongated chamber 18, as well as 30
`the product contact surfaces, should be sterilized to
`ensure that filling is performed in an aseptic environ(cid:173)
`ment. This is accomplished by spraying the above(cid:173)
`described hydrogen peroxide solution through each of
`the spray heads 80,82,84,86 simultaneously, to sterilize 35
`the entire chamber 18. Sterile air is then supplied from
`the air source '76 to the inlet tube 78 to maintain the
`filling compartment 68 at a positive pressure, and thus,
`in an aseptic condition. As will be described in more
`detail below, this sterile air flow also maintains the 40
`drying chamber 72 and dispensing mouth 21 at a posi(cid:173)
`tive pressure, and, therefore, also in an aseptic condi(cid:173)
`tion. Once the sterile air flow to the filling compartment
`68 has been started, the spray heads 82,84,86 may be
`shut off. However, the spray head 80 continuously op- 45
`erates to supply a mist of hydrogen peroxide to the
`spraying chamber 70, during the operation of the appa(cid:173)
`ratus 10, to provide an aseptic barrier between the inlet
`mouth 19 and the drying compartment 72. Thus, the
`hydrogen peroxide mist in the spraying chamber 70, 50
`together with the sterile air flow into the filling com(cid:173)
`partment 68, serves to prevent comtaminants from en(cid:173)
`tering the elongated chamber 18.
`It will be understood that the product contact sur(cid:173)
`faces, such as the interior surface of the filling nozzle 30, 55
`are also sterilized prior to use of the apparatus 10. This
`is accomplished in a manner well known to those skilled
`in the art, for example, by steam sterilization techniques.
`Controllers 92 monitor, record, and control the
`above-described processes and continually regulate 60
`flow rate, pressure, and temperature variables, such as
`the source temperature of the sterilized air, the air pres(cid:173)
`sure in the filling compartment 68, the temperature of
`the air flow through the drying compartment 72, and
`the temperature of the steam for sterilizing the product 65
`contact surfaces. Windows 95 are provided in the side
`of the chamber 18 for viewing the operation of the
`apparatus 10.
`
`4,417,607
`
`6
`The Partitions 60,62 and Seals 64,66,67 of the Chamber
`18
`Before turning to the operation of the container fill(cid:173)
`ing apapratus 10, the partitions 60,62 and the seals
`64,66,67, shown in FIG. 3, will be described in more
`detail. Referring to FIG. 4, the partition 62 includes an
`opening 98, sized to permit the continuous web of con(cid:173)
`tainers 24 to pass therethrough. The contour of the
`opening 98 is generally rectangular with a notch 100
`formed along its upper edge to accommodate the filling
`spouts 25 of the containers 24. The tolerance between
`the edge of the opening 98 and the containers 24 should
`be relatively close to reduce the amount of hydrogen
`peroxide mist passing through the opening 98. How(cid:173)
`ever, such tolerance should not be so close that the
`edges of the opening 98 wipe the web of containers 24
`as they pass therethrough. Because of the relatively
`close tolerances between the edges of the opening 98
`and the web of containers 24, it is preferable that the
`partition 62 be formed of a flexible, resilient material so
`that a slight misalignment between the notch 100 and
`the spout 25 will not prevent advancement of the con(cid:173)
`tainers 24 through the opening 98.
`The partition 60 has an opening 106 of generally the
`same conntour as the opening 98 to permit passage of
`the web of containers 24 therethrough, as shown in
`FIG. 4. However, the opening 106 is substantially
`larger than the opening 98 to permit the previously
`described flow of sterile air through the inlet tube 78
`(FIG. 2) to pass from the filling compartment 68,
`through the opening 106, and into the drying compart(cid:173)
`ment 72. A vent tube 108 is included in the bottom of
`the drying compartment 72, adjacent to the partition 62,
`to provide an outlet for the sterile air after it has trav(cid:173)
`elled the length of the compartment 72.1t will be under(cid:173)
`stood that this flow of sterile air also maintains a posi(cid:173)
`tive pressure in the drying compartment 72 and thus
`reduces any tendency of the hydrogen peroxide mist in
`the spray compartment 70 to migrate through the open(cid:173)
`ing 98. Such positive pressure also prevents contami(cid:173)
`nants from entering the compartment 72 through the
`vent tube 108.
`A small op.ening 110, centered at the bottom of the
`partition 62, adjacent to the vent 108, permits hydrogen
`peroxide condensate formed in the spray compartment
`70 to drain through this opening 110 and into the vent
`108. This vent 108 also serves to drain any hydrogen
`peroxide condensate in the drying compartment 72.
`Accordingly, the bottom walls of the spray compart(cid:173)
`ment and drying compartment are sloped towards this
`drain 108 to provide troughs for carrying condensate
`thereto. The vent 108 is connected by tubing (not
`shown) to a location suitable for disposal of the hydro(cid:173)
`gen peroxide.
`Referring to FIG. 5, the entry port seal 64 is formed
`from an elastomeric membranous material, such as den(cid:173)
`tal dam, and includes a horizontal slit 114, slightly
`greater in length than the width of the continuous web
`of containers 24 to permit such containers 24 to pass
`therethrough. Thus, the edges of the slit 114 seal to the
`outer surface of the empty containers 24 to reduce con(cid:173)
`taminant entry into the chamber 18. The dispensing port
`seals 66,67, shown in FIG. 6, are identical to the entry
`port seal 64, except that they have respective slits 116
`sized to permit filled containers 24 to pass therethrough.
`Like the slit 114, the slits 116 are elastomeric so that
`they (a) expand to permit passage of the containers 24,
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`p. E7
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`

`

`4,417,607
`
`7
`and (b) seal to the outer surface of the containers 24.
`Thus, the seals 66,67, together with the positive pres(cid:173)
`sure in the filling compartment 68, provide a barrier
`against contaminant entry through the mouth 21 and
`into the compartment 68.
`
`The Flexible Containers 24
`The aseptic filling apparatus 10 of the present inven(cid:173)
`tion utilizes containers 24 which are prepackaged in a
`sterile container. Although such prepackaging of the 10
`containers 24 is known in the art, a description of the
`packaging process may be useful in fully understanding
`the operation of the present invention. Referring to
`FIG. 7, the flexible containers 24 are premanufactured
`in continuous web form, precapped, and folded at per- 15
`[orations between adjacent containers, in an accordian
`fashion. The folded containers 24 are then placed in a
`sealed overwrap container 120, comprising, for exam(cid:173)
`ple, a plastic bag. Preferably, this overwrap bag 120 is
`substantially greater in height than the height of the 20
`folded containers 24. Air is evacuated from the over(cid:173)
`wrap bag 120, and the overwrap bag 120, with the con(cid:173)
`tainers 24 therein, is placed in a shipping carton 122.
`The shipping carton 122 is then sealed and placed in a
`sterilizer (not shown) to sterilize the containers 24. Such 25
`sterilization may be accomplished in a conventional
`manner, such as by radiation.
`
`Operation of the Aseptic Filling Apparatus 10
`During operation of the aseptic filling apparatus 10, 30
`the precapped, premanufactured, prepackaged, and
`presterilized containers 24 are fed into the elongated
`chamber 18 in the manner described below. The carton
`122 is opened, and a probe 126, connected by tubing
`(not shown) to the sterile air source 76 (FIG. 1), is 35
`inserted through the wall of the sealed overwrap bag
`120, as shown in FIG. 8, thereby causing the flow of
`sterile air through the probe 126 to inflate the sealed
`overwrap bag 120. An opening 128 is then formed in the
`overwrap bag 120, as by slitting with a knife (not 40
`shown). Preferably, the length of this opening 128 is
`slightly larger than the width of the web of containers
`24 to permit an operator to manually grasp the end of
`the web of containers 24 and pull it through the opening
`128. The operator then connects the leading edge of the 45
`web of containers from the overwrap bag 120 to the
`trailing edge 132 of the web of containers 24 which
`have been previously fed· through the chamber 18. Such
`connection may be made by a pair of clips 134. It will be
`recognized that, although the opening 128 exposes the 50
`contents of the overwrap container 120 to the atmo(cid:173)
`sphere, and thus, to contaminants, the supply of sterile
`air through the probe 126 will provide an air flow
`through the opening 128 to reduce such contamination.
`The peripheral edges formed by the opening 128 are 55
`then fitted around the inlet mouth 19 and attached
`thereto, as by a resilient, elastomeric band 136, to seal
`the opening 128 to the entry port 20. Thus, the over(cid:173)
`wrap bag 120 provides a relatively sterile tunnel for
`passage of containers 24 from the carton 122 to the inlet 60
`mouth 19. The supply of sterile air through the probe
`126 may then be discontinued. The probe 126 may be
`left in the overwrap bag 120, or alternatively, it may be
`removed. However, if the probe 126 is removed, it is
`preferable that the positive pressure in the chamber 18 65
`be sufficiently great to create a positive pressure in the
`overwrap bag 120 to prevent contaminants from enter(cid:173)
`ing through the hole formed by the probe 126.
`
`8
`It will be understood that the foregoing process of
`connecting the overwrap bag 120 to the inlet mouth 19
`may not be necessary in certain environments or for
`certain food products. In such case, the containers 24
`5 may be fed into the chamber 18 without providing the
`relatively sterile tunnel formed by the bag 120.
`The containers 24 are then serially advanced through
`the chamber 18 by the feed means, previously discussed
`in reference to U.S. Pat. No. 4,120,134. Referring again
`to FIG. 3, as the containers 24 pass through the entry
`port seal 64, they enter the sterilizing chamber 70 where
`the continuous hydrogen peroxide mist, dispensed
`through the spray head 80 (FIG. 2), coats the exterior of
`the containers 24 to kill any microorganisms that may
`have contaminated the containers 24 as a result of open(cid:173)
`ing the overwrap bag 120 and exposing of the contain-
`ers 24 to the atmosphere. In this regard, the rate of
`advancement of the containers 24 through the chamber
`18 is dependent upon the degree of contamination or
`"bio-load" on the exterior surfaces of the containers 24,
`and thus, this rate is regulated accordingly. However, it
`will be recognized that the above-described process of
`using the overwrap bag to form a tunnel-like enclosure
`reduces the amount of time that the containers 24 are
`exposed to the atmosphere, and therefore, advanta(cid:173)
`geously reduces the bio-load on such containers 24.
`Consequently, because of this reduced bio-load, the
`required exposure time of the containers 24 to the hy(cid:173)
`drogen peroxide mist in the compartment 70 is reduced,
`thereby permitting more rapid advancement of the con(cid:173)
`tainers 24. It will also be understood that the interior
`surfaces of the containers 24 need not be resterilized,
`since their spouts 25 are capped to prevent contami(cid:173)
`nants from entering the containers 24.
`The containers 24 are then advanced from the steriliz(cid:173)
`ing compartment 70 through the partition 62 and into
`the drying compartment 72 where the hydrogen perox(cid:173)
`ide coating thereon is dryed by a flow of heated sterile
`air. As previously mentioned, this flow of sterile air
`travels from the opening 106 in the partition 60 through
`the entire length of the drying compartment 72 and out
`of the vent pipe 108. The temperature of this air should
`be sufficient to heat the hydrogen peroxide coating
`without damaging the containers 24. Such temperature
`may, for example, be in the range of 150° F. to 190° F.
`If necessary, contact heaters (not shown) may be at-
`tached to the bottom of the drying chamber to boost
`temperatures and reduce temperature differentials in the
`drying chamber 72.
`.
`Heating of the hydrogen peroxide coating, as is well
`known, enhances its antiseptic properties, and thus,
`ensures that the exterior surfaces of the containers 24
`are completely sterile when they enter the filling com(cid:173)
`partment 68. Since the supply of sterile air through the
`inlet tube 78 (FIG. 2) maintains the filling compartment
`68 in an aseptic condition, the sterilized containers 24
`will remain sterile during filling. After the containers 24
`have been filled, they are carried by the support rollers
`23, through the dispensing port seal 66, and onto the
`inclined conveyor 26 where the container separator 52
`(FIG. 1) separates the containers 24 for packaging.
`The present invention, therefore, provides an aseptic
`environment for filling premanufactured, prepackaged,
`and presterilized flexible containers, connected in con(cid:173)
`tinuous web form.
`What is claimed is:
`1. In a container filling apparatus comprising (a) feed
`means for serially advancing containers connected in a
`
`p. E8
`
`

`

`4,417,607
`
`25
`
`55
`
`30
`
`9
`continuous web, from an entry port to a dispensing port,
`and (b) an aseptic filling. compartment between said
`ports having a filling means for filling said containers, a
`method for introducing said containers into said appara(cid:173)
`tus and dispensing them from said apparatus without 5
`introducin