Background of the Invention
(1) Filed of the Invention
[0001] The present invention relates to an aseptic filling machine for filling a liquid
content such as a drink or food or a medicine under aseptic conditions. More particularly,
the present invention relates to an aseptic filling machine showing excellent effects
of keeping asepsis and preventing contamination in a filling zone.
(2) Description of the Related Art
[0002] In carrying out a filling operation in an aseptic or dust-free state, a filling machine
or filling zone is disposed in an aseptic chamber. In general, aseptic air obtained
by passing air through a filtration apparatus having an HEPA (high efficiency particulate
air) filter arranged at the final stage is blown into a clean chamber through a pipe
passage having a large diameter to maintain a positive pressure with aseptic air and
keep asepsis in the aseptic chamber. In order to prevent contamination of a content
with microorganisms and the like, asepsis is kept in the aseptic chamber, and simultaneously,
the pipe passage for blowing out aseptic air, a filling pipe passage including a filling
nozzle and a passage for the content are sterilized.
[0003] According to the conventional technique, sterilization of the aseptic air blow-out
pipe passage is performed independently from sterilization of the filling passage
of the filling machine and the passage for the content. Since the diameter of the
aseptic air blow-out pipe passage is large, sterilization of this pipe passage is
generally carried out in the open system. Accordingly, sterilization cannot be performed
with hot water or super-heated steam (higher than 100°C), and therefore, sterilization
with low-pressure steam (100°C at highest), a mixture of heated gas or heated air
and steam or a mixture of heated air and a chemical sterilizing agent is adopted.
When hot air or super-heated steam is used, even a deep layer portion can be sterilized,
but the latter sterilization method is defective in that only a top layer portion
is sterilized, or sufficient heat is not applied, and therefore, sterilization is
insufficient. Also the method in which sterilization is effected only with a sterilizing
agent is sometimes adopted. However, also in this method, only a top layer portion
is sterilized and microorganisms present below a foreign matter cannot be killed.
Moreover, the mechanism for cleaning and sterilizing the content-filling passage of
the filling machine, the content delivery passage and the like is complicated and
a great deal of labor is required for this operation. A liquid-filling apparatus for
carrying out cleaning and sterilization in a simple manner is disclosed in Japanese
Unexamined Patent Application No. 63-67201. In this apparatus, a nozzle cap having
a liquid discharge pipe connected to the top end of an opening of a filling nozzle
is dismountably combined with a vertical mechanism and a rotary mechanism. At the
sterilization, the filling nozzle cap is attached and used for sterilizing the interior
of the content passage with a sterilizing agent or steam, and at the filling, the
nozzle cap is dismounted and brought down with the liquid discharge pipe so that the
filling operation is not obstructed. However, this filling machine is still insufficient
in that since the liquid discharge pipe comes into the filling zone of the aseptic
chamber and goes out therefrom and many pipes, mechanical parts, parts having a sliding
portion and movable parts are left in the aseptic chamber, the risk of contamination
increases, and furthermore, if the filling head is of the moving type, the mechanism
is complicated. Moreover, since the aseptic air blow-out pipe passage is independently
sterilized, a great deal of labor is necessary.
[0004] Further, a method in which a filling machine or filling zone is arranged in an aseptic
chamber is defective in that since the aseptic chamber is large, construction of the
aseptic zone coats a great deal, a large quantity of aseptic air is necessary for
maintaining a high degree of cheanliness and a great deal of labor is necessary for
the filter-exchanging operation and the cleaning operation. Moreover, since many devices
and machine parts are arranged in the chamber, the risk of contamination of the interior
of the aseptic chamber increases when the machine is adjusted, and many limitations
are imposed on used parts for keeping asepsis.
[0005] Japanese Unexamined Utility Model Publication No. 62-95595 discloses a filling machine
in which aseptic filling is intended. According to the disclosed method, clean air
is injected to the periphery of openings of bottles from the periphery of filling
nozzles to envelop a space between the filling nozzles and the openings of the bottles
with a clean air curtain, whereby asepsis is maintained at the filling step. The consumption
of aseptic air is considerably large, and since asepsis is maintained only by the
air curtain in the open state, it is apprehended that the asepsis will be destroyed
at the operation of adjusting the machine, or contamination will be caused at the
feed and discharge of the bottles.
[0006] A filling machine of the linear and intermittent motion type is generally used for
filling a content into containers formed from a paper or plastic film roll, and in
this case, a local aseptic zone is sometimes formed with the filling zone being as
the center in the interior of the machine, as disclosed in Japanese Examined Patent
Publication No. 61-3502. According to this proposal, a large aseptic chamber is not
necessary and sterilization of the entire machine is not necessary. However, since
a delivery mechanism for the linear and intermittent feeding and a moving mechanism
for the formation of containers are present in the interior of the aseptic zone surrounded
by stationary walls, cleanliness cannot be maintained unless these moving portions
are sufficiently sterilized, and many problems should be solved for maintaining complete
asepsis. Furthermore, these rises a risk of contamination of the aseptic zone when
the machine is adjusted, and many limitations are imposed on parts used, as in the
case where the entire machine is arranged in the aseptic chamber. Moreover, since
acceleration, deceleration and stoppage of the containers are repeated in the delivery
of the linear and intermittent motion system, leakage of the liquid is often caused,
and the operation should be performed at a low speed for avoiding this disadvantage.
Thus, the filling machine of this type is defective in various points as compared
with the rotary type filling machine.
[0007] Clean air to be used in the aseptic chamber or aseptic zone is generally obtained
by using a filtering apparatus comprising HEPA filters arranged at the final stage.
These filters are characterized in that since the pressure loss is small, a large
flow quantity can be obtained, but the dust collection efficiency is not 100% and
is only 99.97% in case of particles having a particle size of 0.3 µm. In contrast,
in case of a membrane filter, a large flow quantity cannot be obtained but the dust
collection efficiency is complete, and particles having an optical particle size within
a range of about 15 to about 0.025 µm can be collected at a dust collection efficiency
of 100%. Since sizes of bacteria and endospores are about 5 to about 0.5 µm, completely
aseptic air can be obtained. However, according to the conventional technique, since
the consumption of air is large, a membrane filter cannot be adopted, and the asepticity
of clean air is limited.
[0008] According to the conventional aseptic filling method, since the air supply pipe passage
of the aseptic chamber is sterilized independently from cleaning and sterilization
of the content filling pipe passage and content delivery passage of the filling machine
by a separate mechanism, the mechanism is complicated and a great deal of labor is
required. Moreover, since sterilization is effected with low-pressure steam, heated
gas, a mixture of heated air and steam, a mixture of heated air and a chemical sterilizing
agent, or a sterilizing agent, or a sterilizing agent alone, troubles are caused and
it is difficult to keep asepsis. For example, only a surface layer portion is sterilized,
sterilization is insufficient in a water-stagnant portion, and bacteria below a foreign
matter cannot be killed by sterilization. Furthemore, in connection with the maintenance
of cleanliness in the aseptic chamber, the risk of contamination is high and the contamination-preventing
mechanism is not completely satisfactory, and improvements are desired.
[0009] Furthemore, according to the conventional aseptic filling method, since the aseptic
zone is large, it is apprehended that the asepsis will be destrolyed unless sterilization
is carefully performed over a broad area, and in order to maintain asepsis, many limitations
are imposed on an operator, and also on parts of the machine and parts disposed in
the chamber. Still further, since a positive pressure has to be maintained, the consumption
of the chamber, it is necessary to scatter the chemical sterilizing agent to the entire
machine by the manual operation. For this purpose, large expenses and a great deal
of labor are necessary. Therefore, improvements are desired.
Summary of the Invention
[0010] It is a primary object of the present invention to solve the foregoing problems of
the conventional techniques and provide a linear or rotary aseptic filling machine,
in which a filling zone is restricted to a local part, maintenance of a positive pressure
with aseptic air is facilitated to improve the contamination-preventing effect, a
aseptic air supply pipe passage is utilized as a part of a pipe passage for recovering
a cleaning liquid or sterilizing fluid to make it possible to simultaneously clean
or sterilize the aseptic air supply pipe passage and a content filling pipe passage
or a content delivery passage, the structure is simple and operational restrictions
for keeping asepsis are reduced, and a high labor-saving effect is attained.
[0011] Another object of the present invention is to solve the problems of the conventional
techniques and provide a rotary aseptic filling machine in which a contamination-preventing
mechanism is excellent, there are no operational restrictions and aseptic filling
is easily accomplished.
[0012] Still another object of the present invention is to provide a rotary aseptic filling
machine in which a filling zone can be maintained in asepsis by using a relatively
small amount of aseptic air and the asepsis is not destroyed by charging of an empty
vessel or discharging of a filled vessel or by approach of an operator to the machine
for the adjustment of the machine.
[0013] In accordance with one fundamental aspect of the present invention, there is provided
an aspect filling machine comprising a filling zone defined by walls, a vessel-supporting
mechanism arranged in the filling zone, a content-filling nozzle arranged in the filling
zone, a pipe passage for supplying the content to the filling nozzle, an air blow-out
opening for producing a positive pressure locally in the filling zone with aseptic
air, a fluid passage-forming connecting member for detachably connecting the filling
nozzle and the air blow-out opening, and a changeover mechanism for connecting the
air blow-out opening alternatively to an aseptic air supply source and a tank for
recovering a cleaning liquid or a sterilizing fluid, wherein the air blow-out opening
forms a part of a pipe passage toe recovering the cleaning liquid or sterilizing fluid.
[0014] In accordance with another aspect of the present invention, there is provided a rotary
aseptic filling machine comprising a rotary table having many vessel-supporting seats,
a filling nozzle located above each vessel-supporting seat, a content feed pipe passage
connected to the filling nozzle, a delivery mechanism for feeding sterilized vessels
to the vessel-supporting seats and a discharge mechanism for taking out content-filled
vessels from the vessel-supporting seats, wherein a filling zone is defined by a rotary
wall having an inner circumferential wall and a top wall, which are formed integrally
with the rotary table, and a fixed outer circumferential wall, a filling nozzle communicating
with the filling zone is arranged on the top wall, an air blow-out opening for producing
a positive pressure locally in the filling zone with aseptic air is arranged on at
least one of the rotary wall and the fixed wall, a fluid passage-forming connecting
member for detachably connecting the filling nozzle and the air blow-out opening and
a changeover mechanism for connecting the air blow-out opening alternatively to a
aseptic air supply source and a tank for recovering a cleaning liquid or a sterilizing
liquid are disposed, and the air blow-out opening forms a part of a pipe passage for
recovering the cleaning liquid or sterilizing fluid.
[0015] In accordance with still another aspect of the present invention, there is provided
a linear aseptic filling machine comprising a filling zone, a vessel-supporting mechanism
arranged in the filling zone, a content-filling nozzle arranged in the filling zone,
a pipe passage for feeding a content to the filling nozzle, a heat forming mechanism
for sterilizing and heat-forming a vessel material sheet and feeding a sterilized
formed vessel to the filling zone, a lid member-heating mechanism for sterilizing
and heating a lid member and feeding the lid member to a scaling step, a sealing mechanism
for sealing the lid member to the content-filled vessel, and a mechanism for punching
the lid-sealed content-filled vessel into a product, wherein the filling zone is defined
by an outer circumferential wall, a filling nozzle communicating with the filling
zone is arranged on a top wall of the outer circumferential wall, an air blow-out
opening for producing a positive pressure locally in the filling zone with aseptic
air is arranged on the outer circumferential wall, a fluid passage-forming connecting
member for detachably connecting the filling nozzle and the air blow-out and a changeover
mechanism for connecting the air blow-out opening alternatively to a aseptic air supply
source and a tank for recovering a cleaning liquid or a sterilizing fluid are arranged,
and the air blow-out opening forms a part of a pipe passage for recovering the cleaning
liquid or sterilizing fluid.
[0016] In accordance with still another aspect of the present invention, there is provided
a rotary aseptic filling machine comprising a rotary table having many vessel-supporting
seats, a filling nozzle arranged above each vessel-supporting seat, a content feed
pipe passage connected to the filling nozzle, a delivery mechanism for feeding sterilized
vessels to the vessel-supporting seats and a discharge mechanism for taking out content-filled
vessels from the vessel-supporting seats, wherein a filling zone is defined by a rotary
wall having an inner circumferential wall and a top wall, which are formed integrally
with the rotary table, and a fixed outer circumferential wall, a filling nozzle communicating
with the filling zone is arranged on he top wall, and an air blow-out opening for
producing a positive pressure locally in the filling zone with aseptic air is arranged
on at least one of the rotary wall and the fixed wall.
Brief Description of the Drawings
[0017]
Fig. 1 is a diagram illustrating in section a main part of one embodiment of the rotary
aseptic filling machine of the present invention.
Fig. 2 is a plane view showing the rotation of the filling zone in Fig. 1 to a delivery
mechanism and a discharge mechanism, disposed before and after the filling zone.
Fig. 3 is a sectional view illustrating a portion of a filling nozzle at the cleaning
or sterilizing step.
Fig. 4 is a diagram illustrating the pipe line at the cleaning or sterilizing step.
Fig. 5 is a diagram illustrating the outline of one embodiment of the linear aseptic
filling machine of the present invention.
Fig. 6 is a sectional view illustrating a portion of a filling nozzle at the cleaning
or sterilizing step in the embodiment shown in Fig. 5.
Detailed Description of the Preferred Embodiments
[0018] The aseptic filling machine of the present invention comprises a filling zone defined
by a wall, a vessel-supporting mechanism arranged in the filling zone, a content-filling
nozzle arranged in the filling zone, a pipe passage for feeding a content to the filling
nozzle and an air blow-out opening for producing a positive pressure locally in the
filling zone with aseptic air, and the aseptic filling machine of the present invention
is prominently characterized in that a fluid passage-forming connecting member for
detachably connecting the filling nozzle to the air blow-out opening and a changeover
mechanism for connecting the air blow-out opening alternatively to an aseptic air
supply source and a tank for recovering a cleaning liquid or a sterilizing fluid are
disposed, and the air blow-out opening forms a part of a pipe passage for recovering
the cleaning liquid or sterilizing fluid.
[0019] More specifically, since the filling zone is defined by the wall, the aseptic zone
is localized, and the diameter of the aseptic air supply pipe passage can be much
reduced, as compared with the case where the entire filling machine is arranged in
an aseptic chamber. Accordingly, the difficulties involved in sterilization in an
open system using a large-diameter pipe passage can be fundamentally eliminated by
adopting a pipe passage of the closed system. At the filling operation, the air blow-out
opening exerts an inherent function of blowing out aseptic air, and at the sterilizing
or cleaning step, the air blow-out opening acts as a part of the pipe passage for
recovering the cleaning liquid or sterilizing fluid. Accordingly, the structure of
the interior of the filling zone can be much simplified, as compared with the case
where both of the air blow-out opening and the opening for recovering the cleaning
liquid or sterilizing fluid are independently arranged. Furthermore, the number of
openings formed in the filling zone can be reduced and the risk of contamination can
be drastically reduced.
[0020] Furthermore, at the sterilizing or cleaning step, the filling nozzle is connected
to the air blow-out opening through a fluid passage-forming connecting member, whereby
the cleaning liquid or sterilizing fluid is allowed to flow through the content feed
pipe passage, the content-filling nozzle, the fluid passage-forming connecting member,
the air blow-out opening and the air feed pipe passage in succession, and the content-filling
system and the aseptic air blow-out system can be simultaneously cleaned or sterilized.
[0021] Especially, since even the aseptic air blow-out system can be sterilized while maintaining
a closed state in this system, a sterilizing fluid having a higher reliability, such
as hot water or super-heated steam, can be used, and therefore, the adaptability to
sterilization can be improved, as compared with the conventional coating of a sterilizing
liquid on a pipe passage of the open system.
[0022] If the air blow-out opening is arranged coaxially with the filling nozzle and annularly
around the periphery thereof and a cap that can be fitted to the air blow-out opening
is used as the fluid passage-forming connecting member, supply of aseptic air at
the filling step is performed in a desirable state where a highest positive pressure
is applied to the content as the enter, and furthermore, changeover between the filling
operation and the sterilizing or cleaning operation can be easily accomplished by
a simple operation of attaching or detaching the cap.
[0023] In the foregoing illustration, the flow direction of the washing liquid or sterilizing
fluid is not limited to one direction, and even if the flow direction is reversed,
no particular disadvantage is brought about. In this case, the above-mentioned pipe
passage acts as the supply pipe passage and the above-mentioned recovery tank acts
as the supply tank. Accordingly, it should be understood that in the instant specification,
the recovery pipe passage means not only the recovery pipe passage but also the supply
pipe passage, and the recovery tank means not only the recovery tank but also the
supply tank.
[0024] In the rotary aseptic filling machine of the present invention, the filling zone
is surrounded by a rotary wall having an inner circumferential wall and a top wall,
which are integrated with a rotary table, and a fixed outer circumferential wall,
whereby the filling zone is locally defined from the outside, and in this filling
zone, there are arranged the filling nozzle and the air blow-out opening and this
rotary aseptic filling machine is characterized in that a positive pressure is maintained
within the filling zone with aseptic air. More specifically, a minimum space necessary
for filling the content into vessels is substantially shielded and localized by the
above-mentioned rotary wall and fixed wall, and therefore, the necessary amount of
aseptic air to be filled into this localized filling zone can be greatly reduced.
This is the first advantage. Since the inner circumferential wall and top walls are
integrated with the rotary table to form a rotary wall, a special driving mechanism
for delivering vessels is not present in this localized aseptic zone including this
rotary wall as a part of the defining wall, and the difficulty of keeping asepsis,
which is due to the presence of such a moving member, is not caused at all. This is
the second advantage. Moreover, by blowing out aseptic air from the air blow-out opening,
a positive pressure can always be maintained in the filling zone, and since aseptic
air flows to the outside from the filling zone through a minute clearance between
the rotary wall and the fixed inner circumferential wall, outer air is not allowed
to flow into the filling zone. Therefore, the filling zone is always kept clean with
aseptic air. Moreover, the filling zone is barriered by the wall. Accordingly, filling
can be accomplished in a completely asepsis, this is the third advantage.
[0025] Since an air blow-out opening having an annular blow-out hole is arranged around
the periphery of each filling nozzle coaxially therewith, aseptic air is supplied
uniformly into the filling zone and aseptic air is allowed to flow smoothly. moreover,
if the structures of the filling nozzle and air blow-out opening are appropriately
arranged, by attaching a cap as described hereinafter, an aseptic air supply pipe
can be used as a part of the pipe passage for recovering the cleaning liquid or sterilizing
fluid. In this case, the filling nozzle and the air blow-out opening can be simultaneously
cleaned or sterilized.
[0026] If the aseptic zone is localized by defining the filling zone by the wall, maintenance
of a positive pressure in the filling zone with aseptic air is facilitated and the
consumption of aseptic air can be much reduced, and use of a membrane filter for rendering
air aseptic becomes possible and the asepticity of air can be increased. Since a positive
pressure is produced in the filling zone, which is barriered by the wall member, with
aseptic air, an operator can adjust the filling machine while he approaches the machine
without destroying the asepsis. Moreover, no substantial asepticity is required for
machine parts used outside the localized aseptic zone. This is another advantage.
Still further, since the aseptic zone is surrounded by the wall member, sterilization
of this zone can be accomplished by spraying of a sterilizing agent by a spray nozzle
instead of the conventional manual spraying of a sterilizing agent. Accordingly, automatization
of steps can be facilitated. This is another great advantage.
[0027] Embodiments of the aseptic filling machine of the present invention will now be described
in detail with reference to the accompanying drawings.
[0028] Fig. 1 is a diagram illustrating in section one embodiment of the rotary aseptic
filling machine of the present invention, Fig. 2 is a plane view showing the relation
of the filling zone in Fig. 1 to the delivery zone and discharge zone before and after
the filling zone, Fig. 3 is a sectional view showing a portion of the filling zone
at the cleaning or sterilizing step, and Fig. 4 is a diagram showing the pipe line
at the cleaning or sterilizing step.
[0029] Referring to the drawings, a filling zone 15 is locally defined by a rotary wall
having a ⊐-shaped section, which comprises an inner circumferential wall 12 and a
top wall 13, which are integrated with a rotary table 10, and a fixed outer circumferential
wall 14. The outer circumferential wall 14 is detachably arranged, and a minute clearance
16 is formed between the rotary wall and the outer circumferential wall 14 so that
rotation of the rotary wall is facilitated and air is blown out through this clearance
16. Many vessel seats 11 are annularly arranged on the rotary table 10 in the filling
zone 15, and a vessel-supporting member 17 is arranged on each vessel seat 11. A vessel
18 is placed on each vessel 11 and a filling nozzle 8 and an air blow-out opening
9 are arranged above each vessel 18 through the top wall 13 in correspondence to each
vessel seat 11. The air blow-out opening 9 is coaxial with the filling nozzle 8 and
has an annular blow-out hole on the periphery thereof. The filling nozzle 8 and air
blow-out opening 9 are arranged to communicate with a filling pipe 5 and an aseptic
air-distributing pipe 19, respectively, through the top wall 13.
[0030] A content (liquid to be filled) is supplied to a filler bowl 4 from a main supply
pipe 23 through a supply flow quantity control valve 1, a content supply pipe 2 and
a rotary joint 3, and the content is filled into the vessel from the filler bowl 4
through the filling pipe 5, a flow meter, a filling valve 7 and the filling nozzle
8.
[0031] A detachable cap 20 is used as a flow passage-forming connecting member for connecting
flow passages of the filling nozzle 8 and air blow-out opening 9. This cap 20 is attached
at the step of cleaning or sterilizing the filling pipe passage, and is detached at
the filling step. Reference numeral 37 represents a cleaning liquid recovery opening
connected to a changeover valve 22, reference numeral 25 represents an air supply
opening of the changeover valve 26, and reference numeral 24 represents a sterilizing
steam recovery opening of the changeover valve 26. The aseptic air-distributing pipe
19 and aseptic air supply pipe 21 form a part of the pipe passage for recovering the
washing liquid or sterilizing fluid at the cleaning or sterilizing step.
[0032] Air supplied to the rotary filling machine proper through a rotary joint 41 is passed
through a mist separator 44 to remove oil mists and dusts and is then supplied to
the air supply opening 25 of the changeover valve 26 and is rendered aseptic through
a film filter 27. Then, aseptic air is supplied to an aseptic air supply opening 38
and is blown out into the filling zone 15 from the air blow-out opening 9 through
the changeover valve 22, the aseptic air feed pipe 21 and the aseptic air-distributing
pipe 19. Blow-out of air from the filling zone 15 is facilitated by the minute clearance
16, and replacement of air in the filling zone 15 with aseptic air and maintenance
of a positive pressure with aseptic air can be easily accomplished.
[0033] A delivery zone 28 and a discharge zone 29 are defined by a fixed outer wall 30,
an outer top wall 31, a table located below a star wheel 32 and the rotary wall. An
aseptic blow-out opening 33 is arranged through the outer top wall 31 of the delivery
zone 28 and discharge zone 29. Reference numeral 34 represents a membrane filter and
reference numeral 35 represents an air supply opening connected to an air supply pipe
passage where a mist separator, a pressure control valve and a pressure gauge are
arranged. Reference 36 represents a minute clearance which exerts a function of facilitating
blow-out of air as well as the minute clearance 16. Reference numeral 39 represents
a spray nozzle and reference numeral 40 represents a cleaning liquid recovery conduit.
[0034] The procedure of cleaning and sterilizing pipe passages will now be described. The
outer peripheral wall 14 of the filling machine is taken out, and the detachable cap
20 as the flow passage-forming connecting member is attached to the filling nozzle
8 and air blow-out opening 9 to form a flow passage. An external recovery pipe 50
connected to a recovery tank 57 is connected to the recovery opening 37 of the changeover
valve 22. Then, an electromagnetic valve 52 is actuated by an electric signal, and
an air cylinder of the changeover valve 22 is actuated by air supplied through the
rotary joint 41 to the filling machine proper at a standstill, whereby the changeover
valve 22 is closed on the side of the aseptic air supply opening 38 to connect the
recovery tank 57 to the air blow-out opening 9. Then, an electromagnetic valve 53
is actuated by an electric signal and the air cylinder of the filling valve 7 is actuated
by air of the same air source to open the filling valve 7 and connect the filling
pipe passage to the pipe passage for recovering the cleaning liquid or sterilizing
fluid.
[0035] When the above operation is completed, the cleaning liquid is caused to flow along
the same passage as the content-filling passage. Namely, the cleaning liquid is fed
to the filling machine at a standstill through the main supply pipe 23, the supply
flow quantity control valve 1, the content supply pipe 2 and the rotary joint 3, is
passed through the filler bowl 4, filling pipe 6, flow meter, filling valve 7, filling
nozzle and flow passage-forming cap 20 of the filling machine, and is recovered in
the recovering tank 57 through the aseptic air blow-out opening 9, the aseptic air-distributing
pipe 19, the aseptic air supply pipe 21, the changeover valve 22, the recovery opening
37 and the recovery pipe 50. The cleaning liquid flows along the above course to clean
the filling pipe passage and remove foreign matters.
[0036] Then, cooled aseptic water is caused to flow along the same course to wash away the
cleaning liquid. The electromagnetic valve 51 is actuated by an electric signal and
the air cylinder of the changeover valve 26 is actuated by air, and the changeover
valve 26 is closed on the side of the air supply opening 25 to connect the sterilizing
steam recovery opening 24 to the membrane filter 27. At this point, an external recovery
pipe 50′ is connected to the sterilizing steam recovery opening 24, and simultaneously,
the electromagnetic valve 52 is actuated by an electric signal to effect changeover
in the changeover valve 22 and close the changeover valve 22 on the side of the recovery
opening 37, whereby the membrane filter 27 is connected to the aseptic air supply
pipe 21. Sterilizing steam, for example, supper-heated steam at 120 to 150°C, is supplied
from the main supply pipe 23 for 20 to 100 minutes, is passed through the supply flow
quantity control valve 1, the content supply pipe 2, the rotary joint 3, the filler
bowl 4, the filling pipe 5, the flow meter 6, the filling valve 7, the filling nozzle
8, the flow passage-forming connecting cap 20, the aseptic air blow-out opening 9,
the aseptic air-distributing pope 19, the aseptic air-distributing pipe 19, the aseptic
air feed pipe 21, the changeover valve 22, the membrane filter 27 and the changeover
valve 26, and is recovered in the external recovery pipe 50′ from the recovery opening
24. After completion of sterilization of the pipe passage, changeover is effected
in the changeover valve 22 again, and cooled aseptic water is caused to flow along
the same course as that of the cleaning liquid to cool the heated pipe passage and
filling machine. Simultaneously, changeover is effected in the changeover valve 26,
and the changeover vale 26 is closed on the side of the sterilizing steam recovering
opening 24 and the membrane filter 27 is connected to the air supply opening 25. The
external steam recovery pipe 50′ is dismounted from the filling machine proper. When
the temperature of the pipe passage and filling machine is lower to room temperature,
supply of aseptic water is stopped and the electromagnetic valve 52 is actuated to
close the changeovervalve 22 on the side of the recovery tank 57 and connect the membrane
filter 27 to the air blow-out opening 9. By this changeover, the aseptic air supply
passage is filled with aseptic air which has passed through the membrane filter 27.
Simultaneously with this changeover in the changeover valve 22, the electromagnetic
valve 53 is actuated to close the filling valve 7. Then, the recovery pipe 50 is taken
out from the recovery opening 37 of the changeover valve 22, and the detachable cap
20 connecting the filling nozzle 8 to the air blow-out opening 9 is dismounted, and
the outer circumferential wall 14 of the filling machine is attached.
[0037] Thus, cleaning and sterilization of the filling pipe passage and the recovery pipe
passage for the cleaning liquid and sterilizing fluid are completed.
[0038] Then, the sterilizing agent is sprayed from the spray nozzle 39 arranged in the filling
zone 15, and aseptic water is further sprayed to render the interior of the filling
zone 15 aseptic. Immediately, aseptic air is introduced through the blow-out opening
9 to produce and maintain a positive pressure in the filling zone 15 and form an aseptic
zone.
[0039] Aseptic air is supplied in the following manner.
[0040] Air supplied to the filling machine from the rotary joint 41 is introduced into the
changeover valve 26 from the air supply opening 25 through the mist separator 54 and
the pressure control valve 55, and air is passed through the membrane filter 27 and
is rendered aseptic. The pipe passage after the membrane filter 27 has been sterilized
according to the above-mentioned procedures, and therefore, this aseptic air is introduced,
without being contaminated, into the filling zone 15 from the aseptic air supply opening
38 through the changeover valve 22, the aseptic air supply pipe 21, the aseptic air-distributing
pipe 19 and the blow-out opening 9. Since the filling zone 15 is defined by the walls,
production of a positive pressure with aseptic air is easily accomplished, and filling
is carried out in the state where a positive pressure is produced in the filling zone
15 with aseptic air.
[0041] As pointed out hereinbefore, the filling pipe passage or content feed passage is
connected to the aseptic air supply pipe passage by attaching the cap 20 to the filling
nozzle 8 and air blow-out opening 9, and therefore, cleaning or sterilization of the
passages can be accomplished simultaneously and assuredly. Accordingly, as compared
with the conventional technique where the pipe passages are independently sterilized
by different mechanisms, the mechanism and structure can be drastically simplified
and the sterilizing effect is improved, and also the contamination-preventing effect
is enhanced. Moreover, the labor and running cost can be greatly reduced.
[0042] The filling is carried out in the state where a positive pressure is maintained within
the filling zone 15, and a positive pressure is also maintained in the delivery zone
28 and delivery zone 29 with aseptic air supplied from the aseptic air blow-out opening
33. In the filling zone 15, a positive pressure is maintained by aseptic air blown
out uniformly into the filling zone 15 from the air blow-out opening arranged coaxially
with the filling nozzle 8 and annularly on the periphery thereof, and aseptic air
flows little by little to the outside through the minute clearance 16. Accordingly,
aseptic air is blown out uniformly without uneven distribution, and an aseptic zone
not contaminated from the outside is formed in the filling zone 15. The degree of
the positive pressure produced in the filling zone 15 with aseptic air is such that
the pressure in the filling zone 15 is higher by 0.1 to 30 mmAg, preferably by 1
to 10 mmAg, than the pressure in the outside.
[0043] In the filling zone 15 where a positive pressure is thus maintained with aseptic
air, the filling is carried out in the following manner.
[0044] The content fed through the main pipe passage is fed through the flow quantity control
valve 1, the content supply pipe 2 and the rotary joint 3 and stored in the filler
bowl 4. The filling valve 7 is opened by a filling-initiating electric signal. The
content is fed from the filler bowl 4 and passed through the content-supplying filling
tube 5, flow meter 6 and the filling valve 7, and is filled into a vessel from the
filling nozzle 8. By a filling-stopping electric signal emitted from the flow meter
6, the filling valve 7 is closed and the filling is terminated.
[0045] Figs. 5 and 6 illustrate one embodiment of the linear filling machine of the present
invention. Fig. 5 is a diagram illustrating the outline and Fig. 6 is a sectional
view of a portion of the filling nozzle at the cleaning or sterilizing step. In Figs.
5 and 6, reference numeral 5a represents a filling pipe, reference numeral 6a represents
a flow meter, reference numeral 7a represents a filling valve, reference numeral 8a
represents a filling nozzle, reference numeral 9a represents an air blow-out opening,
reference numeral 20a represents a detachable flow passage-forming connecting member,
that is, a cap, and reference numeral 21a represents an aseptic air supply pipe which
forms a part of a pipe for recovery of the cleaning liquid or sterilizing fluid. Reference
numeral 38a represents an aseptic air supply opening communicating with the aseptic
air supply pipe passage, and reference numeral 37a represents an opening for recovery
of the cleaning liquid or sterilizing fluid, which communicates with the recovery
tank. The operations conducted in the filling machine are now described. A vessel
material 58 is sterilized by an aseptic agent 59, passed through a supporting roll
60, dried by a heater 61 and formed in a vessel-forming device 62. A content is filled
in the formed vessel 63 through the filling nozzle 8a arranged in the filling zone.
A lid material 64 is passed through a sterilizing agent 65 and dried by a heater 66.
The content-filled vessel is lidded, sealed by a scaling device 67 and punched out
by a punching device 68 to obtain a product 71. A scrap 70 is wound through a supporting
roll 69.
[0046] The cleaning and sterilization of the pipe passages are carried out according to
the following procedures.
[0047] The flow passage-forming cap 20a is attached to the filling nozzle 8a and the air
blow-out opening 9a to form a flow passage. Changeover is effected in the changeover
valve 22a so that the aseptic air supply pipe passage 21a is connected to the cleaning
liquid or sterilizing fluid recovery opening 37a. The recovery pipe communicating
with the cleaning liquid or sterilizing fluid recovery tank is connected to the recovery
opening 37a. The filling valve 7a is opened and the cleaning liquid is caused to flow
from the content supply pipe passage through the filling pipe 5a. The cleaning liquid
is introduced into the changeover valve 22a through the filling pipe 5a, the flow
meter 6a, the filling valve 7a, the filling nozzle 8a, the cap 20a, the aseptic air
blow-out opening 9a and the aseptic air supply pipe 21a, and the cleaning liquid is
recovered into the recovery tank from the recovery opening. When the cleaning is terminated,
aseptic water is caused to flow along the same course to wash away the cleaning liquid.
Then, the sterilizing fluid, for example, hot water at 120 to 150°C, is caused to
flow for 20 to 50 minutes along the same course to sterilize the pipe passage. Since
the distance between the aseptic air supply opening 38a and the membrane filter 27a
is very short, sufficient heating and sterilization are effected by heat conducted
through the pipe passage wall from hot water passing through the changeover valve
22a. After termination of the sterilization, aseptic water is caused to flow to cool
the pipe passages. after completion of the cooling, the changeover valve 22a is closed
on the side of the recovery opening 37a to connect the aseptic air supply opening
38a to the aseptic air supply tube 21a, and the interior of the pipe passages is filled
with aseptic air. Simultaneously, the filling valve 7a is closed and the cap 20a is
taken out to separate the filling pipe passage from the aseptic air blow-out passage.
[0048] In the filling machine of the present invention, the filling zone is defined and
localized by walls, and a filling nozzle is arranged in this filling zone and an aseptic
air blow-out opening having an annular blow-out hole arranged coaxially with the filling
nozzle and on the periphery thereof is arranged just above the filling nozzle. Accordingly,
the effect of preventing contamination of the aseptic zone can be enhanced.
[0049] Since the content filling pipe passage or content feed pipe passage is connected
to the aseptic air supply pipe passage by attaching the detachable flow passage-forming
connecting member to the filling nozzle and air blow-out opening, the aseptic air
supply pipe passage forms a part of the cleaning liquid or sterilizing fluid recovery
pipe passage at the cleaning or sterilizing step, and the content filling pipe passage
or content feed pipe passage and the aseptic air supply passage can be simultaneously
cleaned or sterilized by the same mechanism. Therefore, it is not necessary to perform
sterilization of the aseptic air blow-out pipe passage independently by a different
mechanism as in the conventional technique. Furthermore, since the aseptic air blow-out
opening (air nozzle) and the aseptic air supply pipe passage form a part of the cleaning
liquid or sterilizing fluid recovery pipe passage, these members need not be independently
disposed and the number of pipes and machine parts arranged in the filling zone can
be reduced, and therefore, the risk of contamination is eliminated and limitations
imposed on the operations are moderated.
[0050] Moreover, since the aseptic air blow-out opening forms a part of the cleaning liquid
or sterilizing fluid recovery pipe passage, the pipe passage can be washed or sterilized
in the closed system. Accordingly, foreign matters can be easily removed by cleaning,
and after this cleaning, sterilization can be accomplished by hot water or super-heated
steam. Therefore, heat is conducted even to a deep portion and complete sterilization
becomes possible.
[0051] In the rotary aseptic filling machine of the present invention, since the filling
zone is defined and localized by the rotary wall and fixed outer circumferential wall,
aseptic air is blown out from the air blow-out opening formed on the wall member and
a positive pressure is maintained in the filling zone by aseptic air while causing
aseptic air to flow to the outside from the minute clearance between the rotary wall
and the outer circumferential wall, intrusion of microorganisms or dusts presumed
to contain microorganisms therein into the filling zone from the outside can be prevented
and a good aseptic zone is formed in the filling zone. Moreover, since the aseptic
zone is barriered by the wall member, the filling can be performed in a complete asepsis.
Since a positive pressure is kept locally in the filling zone with aseptic air and
the consumption of aseptic air can be reduced, it becomes possible to use a membrane
filter. Therefore, a positive pressure can be maintained in the filling zone with
completely aseptic air, and the stability against bacterial contamination is increased
as compared with the case where an HEPA filter is sued. Since the interior of the
filling zone is doubly barriered by the wall member and aseptic air, an operator can
adjust the filling machine while approaching the machine sufficiently without destroying
the asepsis. Moreover, since the volume of the filling zone to be rendered aseptic
is small and the number of machine parts arranged in the filling zone is small, the
risk of contamination is further reduced. Especially, since the filling zone is defined
by the rotary wall having the inner circumferential wall and top wall integrated with
the rotary table and the fixed outer circumferential wall, any particular driving
mechanism need not be disposed for delivery of vessels in the filling zone and a complicated
operating mechanism is not present in the interior of the aseptic zone. Therefore,
there is no risk of bacterial contamination by these mechanisms. Moreover, when the
filling machine of the rotary type is used, vessels can be delivered continuously,
and the risk of dropping of a filled liquid content under shaking, expected to occur
in case of the intermittent delivery, is eliminated, and the continuous operation
can be performed at a high speed.
1. An aseptic filling machine comprising a filling zone defined by walls, a vessel-supporting
mechanism arranged in the filling zone, a content-filling nozzle arranged in the filling
zone, a pipe passage for supplying the content to the filling nozzle, an air blow-out
opening for producing a positive pressure locally in the filling zone with aseptic
air, a fluid passage-forming connecting member for detachably connecting the filling
nozzle and the air blow-out opening, and a changeover mechanism for connecting the
air blow-out opening alternatively to an aseptic air supply source and a tank for
recovering a cleaning liquid or a sterilizing fluid, wherein the air blow-out opening
forms a part of a pipe passage for recovering the cleaning liquid or sterilizing fluid.
2. An aseptic filling machine as set forth in claim 1, wherein the filling nozzle
is arranged on the top wall of the filling zone so that the nozzle is directed downward.
3. An aseptic filling machine as set forth in claim 1, wherein the air blow-out opening
is arranged coaxially with the filling nozzle and annularly on the periphery thereof.
4. An aseptic filling machine as set forth in claim 1, wherein the fluid passage-forming
connecting member is a cap.
5. An aseptic filling machine as set forth in claim 1, wherein the fluid passage-forming
connecting member is clamped to the air blow-out opening to form a pipe for recovering
the cleaning liquid or sterilizing fluid.
6. An aseptic filling machine as set forth in claim 1, wherein the changeover mechanism
for connecting the air blow-out opening alternatively to the aseptic air supply source
and the tank for recovering the cleaning liquid for sterilizing fluid is an automatically
controlled changeover valve.
7. An aseptic filling machine as set forth in claim 1, wherein a membrane filter is
used as a filter of the aseptic air supply source.
8. An aseptic filling machine as set forth in claim 1 or 7, wherein an automatically
controlled changeover valve for connecting an air supply opening of an air filter
of the aseptic air supply source alternatively to the air supply pipe passage and
the sterilizing steam recovery opening is disposed.
9. A rotary aseptic filling machine comprising a rotary table having many vessel-supporting
seats, a filling nozzle located above each vessel-supporting seat, a content feed
pipe passage connected to the filling nozzle, a delivery mechanism for feeding sterilized
vessels to the vessel-supporting seats and a discharge mechanism for taking out content-filled
vessels from the vessel-supporting seats, wherein a filling zone is defined by a rotary
wall having an inner circumferential wall and a top wall, which are formed integrally
with the rotary table, and a fixed outer circumferential wall, a filling nozzle communicating
with the filling zone is arranged on the top wall, an air blow-out opening for producing
a positive pressure locally in the filling zone with aseptic air is arranged on at
least one of the rotary wall and the fixed wall, a fluid passage-forming connecting
member for detachably connecting the filling nozzle and the air blow-out opening and
a changeover mechanism for connecting the air blow-out opening alternatively to an
aseptic air supply source and a tank for recovering a cleaning liquid or a sterilizing
liquid are disposed, and the air blow-out opening forms a part of a pipe passage for
recovering the cleaning liquid or sterilizing fluid.
10. An aseptic filling machine as set forth in claim 9, wherein a minute clearance
allowing blow-out of air is formed among the fixed outer periphery wall, the rotary
top wall and the rotary table.
11. An aseptic filling machine as set forth in claim 9, wherein the peripheries of
the delivery mechanism and discharge mechanism are covered by a fixed wall and an
air blow-out opening is arranged on the fixed wall to produce a positive pressure
in the interior thereof with aseptic air.
12. A linear aseptic filling machine comprising a filling zone, a vessel-supporting
mechanism arranged in the filling zone, a content-filling nozzle arranged in the filling
zone, a pipe passage for feeding a content tot he filling nozzle, a heat forming mechanism
for sterilizing and heat-forming a vessel material sheet and feeding a sterilized
formed vessel to the filling zone, a lid member-heating mechanism for sterilizing
and heating a lid member and feeding the lid member to a sealing step, a sealing mechanism
for sealing the lid member to the content-filled vessel, and a mechanism for punching
the lid-sealed content-filled vessel into a product, wherein the filling zone is defined
by an outer circumferential wall, a filling nozzle communicating with the filling
zone is arranged on a top wall of the outer circumferential wall, an air blow-out
opening for producing a positive pressure locally in the filling zone with aseptic
air is arranged on the outer circumferential wall, a fluid passage-forming connecting
member for detachably connecting the filling nozzle and the air blow-out opening and
a changeover mechanism for connecting the air blow-out opening alternatively to an
aseptic air supply source and a tank for recovering a cleaning liquid or a sterilizing
fluid are arranged, and the air blow-out opening forms a part of a pipe passage for
recovering the cleaning liquid or sterilizing fluid.
13. An aseptic filling machine as set forth in claim 12, wherein the heat forming
mechanism, lid heating mechanism and sealing mechanism are covered with the outer
circumferential wall and an air blow-out opening is arranged on the outer circumferential
wall to produce a positive pressure in the interior thereof with aseptic air.
14. A rotary aseptic filling machine comprising a rotary table having many vessel-supporting
seats, a filling nozzle arranged above each vessel-supporting seat, a content feed
pipe passage connected to the filling nozzle, a delivery mechanism for feeding sterilized
vessels to the vessel-supporting seats and a discharge mechanism for taking out content-filled
vessels from the vessel-supporting seats, wherein a filling zone is defined by a rotary
wall having an inner circumferential wall and a top wall, which are formed integrally
with the rotary table, and a fixed outer circumferential wall, a filling nozzle communicating
with the filling zone is arranged on the top wall, and an air blow-out opening for
producing a positive pressure locally in the filling zone with aseptic air is arranged
on at least one of the rotary wall and the fixed wall.
15. A rotary aseptic filling machine as set forth in claim 14, wherein a minute clearance
allowing flow-out of air is formed among the fixed outer circumferential wall, the
rotary top wall and the rotary table.
16. A rotary aseptic filling machine as set forth in claim 14, wherein a annular air
blow-out opening is arranged on the top wall coaxially with the filling nozzle and
on the periphery thereof.
17. A rotary aseptic filling machine as set forth in claim 14, wherein the peripheries
of the delivery mechanism and discharge mechanism are covered with a fixed wall and
an air blow-out opening is arranged on the fixed wall to produce a positive pressure
in the interior thereof with aseptic air.