An apparatus and a method for filling containers

Abstract

 An apparatus (1) for filling containers (2) comprising: a conveying device (8) having at least one unit (13) for receiving and retaining a relative container (2) and which is fed by the conveying device (8) along a given horizontal path (P); at least one filling device (14) for feeding a pourable product into the container (2) as the unit (13) travels along the path (P); and at least one ultrasound generating device (30) selectively activated after the container (2) has been filled with the pourable product and adapted to apply ultrasonic waves above the level of the pourable product in the container (2) to collapse foam; the ultrasound generating device (30) comprises an emitter (31) arranged below the top (4) of the container (2) carried by the unit (13); the apparatus (1) further comprises a reflecting surface (32) placed above the container (2) carried by the unit (13), receiving the ultrasonic waves from the emitter (31) and reflecting the ultrasonic waves towards the top (4) of the container (2).

Description

[0001] The present invention relates to a an apparatus and a method for filling containers with pourable products, in particular carbonated liquids, such as sparkling water, soft drinks and beer, to which reference is made hereinafter purely by way of example.

[0002] The present invention may be also used to particular advantage for any type of container, such as containers or bottles made of glass, plastics, aluminum, steel and composites, and for any type of pourable product, such as non-carbonated liquids (including still water, juices, teas, sport drinks, liquid cleaners, wine, etc), emulsions, suspensions and high viscosity liquids.

[0003] In the bottling of carbonated liquids, like beer in glass bottles, a system is known comprising a feed line for feeding a succession of empty bottles to a filling machine, in turn comprising a filling carousel, which is mounted to rotate continuously about a vertical axis, receives the empty bottles successively, feeds pressurized gas, such as carbon dioxide, into the bottles to pressurize them, fills the bottles with the carbonated liquid, decompresses the full bottles, and feeds the bottles to a capping machine connected to the filling machine by at least one transfer wheel, and which closes the bottles with caps.

[0004] For reasons of economy, commercial containers are not such larger than the volume required for accommodating of the contents. Thus, during filling operations it is common for some amount of liquid in the form of foam to bubble over the top of the container prior to the container being capped or sealed. The product loss can be as high as ten percent, which translates into higher cost for the consumer or lower profitability for the bottler, or both.

[0005] To reduce this product loss, some filling lines include a dwell station that allows for the product foam in a recently filled container to settle prior to capping.

[0006] Other filling lines include a short suction pipe adapted to be introduced into the container to be sealed, and a suction system whereby the foam over the top surface of the liquid is removed and optionally recycled into the product reservoir.

[0007] Some filling lines may also use blast nozzles for blowing any drops and residual foam from the surfaces to be sealed or capped.

[0008] Some filling lines reduce the temperature of the liquid at the mixing tanks or other reservoirs to reduce foaming.

[0009] Other filled products are purposefully overfilled to compensate for lost product in the form of foam and thereby achieve the desired net fill volume, which results in undesirable product loss.

[0010] A possible solution to the problem of the foam at the end of the filling operation is proposed in US 4,295,502, which discloses that foam can be collapsed in place by subjecting the foam structure to high-frequency wave radiation from a source spaced above the liquid. The portion of liquid forming the foam then again becomes part of the liquid content of the container, rather than being wasted.

[0011] Sound waves, primarily those above the sonic range, are used with the high-frequency range of about 20,000 Hz. The ultrasonic radiation is emitted by an ultrasound generating device placed above the containers and is directed to the top of the liquid. This results in a concentration of the radiation on the foam structure.

[0012] The apparatus disclosed in US 4,295,502 uses a plurality of parallel ultrasonic wave fields radiating into the foam by an appropriately designed horn or sonotrode. After an exposure time of just 0.2 to 0.3 seconds the foam is reportedly destroyed to an extent not usually attainable by a suction arrangement.

[0013] It is also specified that when sonotrodes are used for the radiation of ultrasonic waves, it is advantageous to combine a plurality of sonotrodes into a bank of sonotrodes or into an aggregate sonotrode. The individual sonotrodes are advantageously constructed as pins and arranged parallel to one another on a metal block to permit them to radiate the individual ultrasonic wave fields side by side and close together into the foam. In order that the foam layer over the liquid may be fully covered even by a focused radiation field, it is advisable to adapt the aggregate sonotrode to the cross-sectional configuration of the container in the area of the liquid level.

[0014] This type of solution is however difficult to implement in modern filling machines, as it requires a large space above the containers, which is completely occupied by filling heads to deliver the product into the containers.

[0015] Another possible solution is disclosed in US 8,128,730, which discloses the use of one single defoaming sonotrode, which has particularly reduced dimensions but is once again placed in the part of the filling apparatus extending above the containers.

[0016] The applicant has observed that two important factors to obtain an effective collapsing of the foam by using ultrasonic waves are the rapidity and the precision of the action of the ultrasound generating apparatus. In practice, it is necessary to act on the foam immediately after the end of the filling operation and to precisely focus the ultrasonic waves on the top of the containers.

[0017] Due to the fact that, in the known filling machines, the zone above the containers is already occupied by the filling devices, which are mounted side by side on the rotating carousel, the solutions disclosed in US 4,295,502 and US 8,128,730 do not allow a positioning of the ultrasound generating apparatus capable of ensuring a precise and rapid action on each container immediately after the end of the filling operation.

[0018] It is an object of the present invention to provide an apparatus for filling containers, designed to eliminate the aforementioned drawback, and which is cheap and easy to implement.

[0019] According to the present invention, there is provided an apparatus for filling containers as claimed in Claim 1.

[0020] The present invention also relates to a method for filling containers as claimed in Claim 9.

[0021] A non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:

Figure 1 shows a schematic top plan view, with parts removed for clarity, of a preferred embodiment of a container filling apparatus according to the present invention;

Figure 2 shows a larger-scale perspective view, with parts removed for clarity, of a part of the Figure 1 apparatus;

Figures 3 shows a larger-scale, partly sectioned side view of a carry-and-fill assembly of the Figure 1 apparatus for carrying and filling a relative container; and

Figure 4 shows a partly sectioned side view of the Figure 3 carry-and-fill assembly in a different operative position.

[0022] Number 1 in Figure 1 indicates as a whole an apparatus for filling containers, in particular bottles 2 (Figures 2 to 4), with pourable products, in the example shown sparkling water or carbonated beverages, including soft drinks and beer.

[0023] As visible in Figures 2 to 4, each bottle 2 has a longitudinal axis A and is bounded at the bottom by a bottom wall 3 substantially perpendicular to axis A, and has a top neck 4 substantially coaxial with the axis A.

[0024] In the example shown, the bottles 2 filled by apparatus 1 are made of glass; however, apparatus 1 may be also used for other types of containers, such as containers made of aluminum, steel, plastics and composites. Moreover, the containers used in apparatus 1 may be filled with any type of pourable product, including non-carbonated liquids (such as still water, juices, teas, sport drinks, liquid cleaners, wine, etc), emulsions, suspensions and high viscosity liquids.

[0025] With reference to Figures 1 and 2, apparatus 1 basically comprises a rotative filling machine 5, an input star wheel 6 for supplying a succession of empty bottles 2 to machine 5, and an output star wheel 7 for receiving a succession of filled bottles 2 from machine 5.

[0026] Machine 5 basically comprises a carousel 8, which is mounted to rotate continuously (anticlockwise in Figure 1) about a vertical axis B perpendicular to the Figure 1 plane. The carousel 8 receives the empty bottles 2 from input star wheel 6 at a first transfer station 10 and releases the filled bottles 2 to output star wheel 7 at a second transfer station 11.

[0027] Machine 5 further comprises a plurality of carry-and-fill assemblies 12, which are equally spaced about axis B, are mounted along a peripheral edge of carousel 8, and are moved by the carousel 8 along a path P extending about axis B and through stations 10 and 11.

[0028] As shown in Figures 2 and 3, each assembly 12 comprises a support unit 13 adapted to receive and retain a relative bottle 2 in a vertical position, in which such bottle 2 has its axis A parallel to the axis B of carousel 8, and a filling device 14 for feeding the pourable product into a bottle 2 as the support unit 13 travels along path P.

[0029] Each filling device 14 is conveniently arranged above the bottle 2 to be filled.

[0030] With reference to Figures 3 and 4, support unit 13 of each assembly 12 comprises gripping means 15, known per se and only schematically shown, which act on top neck 4 of the relative bottle 2 to support it in a suspended position.

[0031] Filling device 14 of each assembly 12 basically comprises a support block 16 secured, in a manner known per se and not shown, to the carousel 8 and terminating, towards the bottle 2, with a hollow body 17, in the example shown having a tubular configuration; filling device 14 of each assembly 12 further comprises a filling head 18 engaging hollow body 17 in a fluid-tight and axially displaceable manner and adapted to cooperate with the top neck 4 of the relative bottle 2 to perform the filling operation.

[0032] In particular, each filling head 18 defines a filling mouth 19 and has a lower end 18a facing the top neck 4 of the relative bottle 2 and provided with a gasket (known per se and not shown).

[0033] Each filling head 18 is supported by the relative support block 16 in a movable manner along a vertical axis C, parallel to axis B and coaxial to the axis A of the relative bottle 2; more specifically, each filling head 18 can be displaced between a rest position (Figure 4), in which it has its lower end 18a spaced from the top neck 4 of the relative bottle 2, and a filling position (Figure 3), in which it has the gasket of its lower end 18a in contact with the top neck 4 of the relative bottle 2 so that the relative filling mouth 19 communicates with the inside of the bottle 2 in a fluid-tight manner towards the outside.

[0034] With reference to Figures 3 and 4, each filling head 19 defines a central conduit 20, a first annular conduit 21 extending around the conduit 20, and a second annular conduit 22 formed between the side wall of the filling head 18 and the outer side wall of the conduit 21.

[0035] Support block 16 of each filling device 14 internally defines three different fluid circuits, known per se and only schematically shown in Figure 3:

• a product circuit 23 for connecting, through an ON/OFF valve (known per se and not shown), the relative annular conduit 21 to a tank (known per se and not shown) containing the pourable product;
• a pressurization circuit 24 for connecting, through an ON/OFF valve 25, the relative central conduit 20 to a chamber 26 filled with a pressurization fluid, e.g. carbon dioxide; and
• a decompression circuit 27 for connecting, through an ON/OFF valve 28, the relative annular conduit 22 to a chamber 29 in turn connected to a discharge device (known per se and not shown).

[0036] With reference to Figures 1, 2 and 4, machine 5 further comprises an ultrasound generating device 30, which can be selectively activated to apply ultrasonic waves above the level of the pourable product in the already-filled bottles 2 so as to collapse foam.

[0037] In practice, ultrasound generating device 30 is arranged peripherally with respect to carousel 8 and in a fixed position along path P; more specifically, in the example shown, ultrasound generating device 30 is arranged adjacent to output star wheel 7.

[0038] Ultrasound generating device 30 is cyclically activated to direct ultrasonic waves on each bottle 2 passing by the device 30 and already filled with the pourable product. In other words, ultrasound generating device 30 is activated at the end of each filling operation carried out on each bottle 2.

[0039] As visible in Figures 2 and 4, ultrasound generating device 30 comprises an emitter 31 arranged below the plane on which the tops of the bottles 2 advanced along path P lie; at least one reflecting surface 32 is provided for receiving the ultrasonic waves from emitter 31 and for reflecting the ultrasonic waves towards the top neck 4 of each bottle 2 passing by the ultrasound generating device 30.

[0040] In the example shown, emitter 31 is also arranged below the plane on which lower ends 18a of filling heads 18 lie.

[0041] According to the preferred embodiment of the present invention disclosed in Figures 2 and 4, each filling device 14 is provided with a relative reflecting surface 32 in use placed above the relative bottle 2.

[0042] In particular, each reflecting surface 32 is defined by the lower end 18a of the relative filling head 18 and/or by the lower end of the corresponding hollow body 17.

[0043] In practice, the ultrasonic waves generated by emitter 31 are reflected by the lower end face of the filling device 14 passing by the ultrasound generating device 30 and can penetrate the open bottle 2 positioned just below such filling device 14 so as to collapse or eliminate foam from the bottle top neck 4.

[0044] With particular reference to figure 2 and 4, ultrasound generating device 30 comprises a freestanding support frame 33 positioned adjacent to, and upstream from, output star wheel 7 along path P, emitter 31 and a transducer 34 interposed between emitter 31 and support frame 33.

[0045] More specifically, emitter 31 has an upper planar surface 35 oriented in such a way to focus the ultrasonic waves on the lower end 18a of the filling device 14 in which the filling operation of a relative bottle 2 has just been completed.

[0046] Emitter 31 further comprises a lower portion 36 coupled to transducer 34, which is in turn connected to a power supply (known per se and not shown) to supply power at a frequency selected so as to cause ultrasonic vibration of the emitter 31.

[0047] As visible in Figures 2 and 4, upper surface 35 of emitter 31 is located below the plane on which lower ends 18a of filling heads 18 lie.

[0048] Operation of apparatus 1 will now be described with reference to the filling of one bottle 2, and therefore to one carry-and-fill assembly 12, and as of the instant in which such bottle 2 is received by gripping means 15 of the assembly 12 from input star wheel 6 in order to be filled with the pourable product.

[0049] In this condition, the bottle 2 is centered with respect to the relative filling device 14 by moving the filling head 18 from the rest position to the filling position. In particular, the gasket of the lower end 18a of the filling head 18 contacts the top neck 4 of the bottle 2, which reaches a position coaxial to the filling head 18. In practice, the axis A of the bottle 2 is coaxial to the axis C of the filling head 18.

[0050] At this point, valve 25 of pressurization circuit 24 is opened (the valve of product circuit 23 and valve 28 of decompression circuit 27 are in a closed condition) and is maintained in that condition up to the moment in which pressure in the bottle 2 is equal to pressure in chamber 26. Then, the valve 25 is closed.

[0051] By opening the valve of product circuit 23, the actual filling of the bottle 2 with the pourable product can be started. This step ends when the product reaches the desired level in the bottle 2.

[0052] The next step is the decompression of the bottle 2, which is achieved by connecting the bottle 2 with decompression circuit 27.

[0053] At this point, the filling head 18 can be moved to the rest position. In this stage, some amount of product in the form of foam may bubble over the top of the bottle 2. This phenomenon can be avoided by activating ultrasound generating device 30.

[0054] In particular, the ultrasonic waves generated by emitter 31 are reflected by the reflecting surface 32 of the relative filling device 14 and can penetrate the open bottle 2 positioned just below such filling device 14 so as to eliminate foam from the bottle top neck 4.

[0055] The advantages of apparatus 1 and the filling method according to the present invention will be clear from the foregoing description.

[0056] In particular, thanks to the fact that the ultrasonic waves are reflected towards the top of each bottle 2 by a reflecting surface 32 placed in use just above the relative bottle 2, the ultrasound generating device 30 can be arranged in any suitable position in the filling apparatus 1 and is effective in terms of rapidity and precision of action as it were placed exactly above the bottle 2, in which foam has to be collapsed.

[0057] In this way, there is no need to implement the ultrasound generating device 30 in a zone of the machine 5 which is already crowded with other devices (such as the filling devices 14).

[0058] Thanks to the effectiveness of ultrasound generating device 30, it is possible to reduce the duration of the decompression step and/or to increase the filling speed; in both cases, by maintaining the same output rate, the number of filling devices 14 on carousel 8 can be reduced with a consequent reduction of the diameter and cost of machine 5.

[0059] The new solution also allows to increase cleanliness of the machine 5, as less foam is lost in the machine area.

[0060] Clearly, changes may be made to apparatus 1 and the filling method as described and illustrated herein without, however, departing from the scope as defined in the accompanying claims.

[0061] In particular, ultrasound generating apparatus 30 may be arranged in any position along the filling line up to the station in which bottles 2 or the containers in general are capped.

[0062] Moreover, the apparatus may be also used for non-carbonated pourable products, for which a contact between each filling head 18 and the relative container is not necessary.

Claims

1. An apparatus (1) for filling containers (2) comprising:

- a conveying device (8) having at least one unit (13) for receiving and retaining a container (2) and which is fed by the conveying device (8) along a path (P);

- at least one filling device (14) for feeding a pourable product into the container (2) as the unit (13) travels along said path (P), said filling device (14) being placed above the container (2) to be filled; and

- at least one ultrasound generating device (30) selectively activated after the container (2) has been filled with the pourable product and adapted to apply ultrasonic waves above the level of the pourable product in the container (2) to collapse foam;
characterized in that said ultrasound generating device (30) comprises an emitter (31) arranged below the top (4) of the container (2) carried by said unit (13), and in that said apparatus (1) further comprises a reflecting surface (32) placed above said container (2) carried by said unit (13), receiving the ultrasonic waves from said emitter (31) and reflecting said ultrasonic waves towards the top (4) of the container (2).

2. The apparatus as claimed in claim 1, wherein said filling device (14) comprises a filling mouth (18, 19) for pouring the pourable product into said container (2), and wherein said emitter (31) is arranged below a lower end (18a) of said filling mouth (18, 19).

3. The apparatus as claimed in claim 1 or 2, wherein said reflecting surface (32) is carried by said filling device (14).

4. The apparatus as claimed in claim 2 or 3, wherein said reflecting surface (32) is defined by a lower end (18a) of said filling device (14) facing the top (4) of the relative container (2).

5. The apparatus as claimed in anyone of claims 2 to 4, wherein said filling device (14) comprises a hollow supporting element (17) secured to said conveying device (8) and having a lower end facing the top (4) of the container (2) carried by said unit (13), wherein said filling mouth (18, 19) engages said lower end of said hollow supporting element (17) in a displaceable manner between a filling position, in which the lower end (18a) of the filling mouth (18, 19) contacts the top (4) of the container (2), and a rest position, in which the lower end (18a) of the filling mouth (18, 19) is spaced from the top (4) of the container (2), and wherein said reflecting surface (32) is defined by said lower end (18a) of the filling mouth (18, 19) and/or by said lower end of said hollow supporting member (17).

6. The apparatus as claimed in anyone of claims 2 to 5, wherein said emitter (31) has an upper surface (35) located below said lower end (18a) of said filling mouth (18, 19), and wherein said ultrasound generating device (30) further comprises an ultrasonic transducer (34) coupled to a lower end (36) of said emitter (31).

7. The apparatus as claimed in anyone of the foregoing claims, wherein said conveying device comprises a conveyor carousel (8), which is mounted to rotate about a vertical axis (B) to define said path (P), comprises a plurality of units (13) for receiving a retaining respective containers (2), and comprises, for each unit (13), a filling device (14).

8. The apparatus as claimed in claim 7, wherein said ultrasound generating device (30) is arranged peripherally with respect to said carousel (8) and in a fixed position along said path (P).

9. The apparatus as claimed in claim 8, further comprising an input station (6) for feeding a succession of empty containers (2) to said carousel (8), and an output station (7) for receiving a succession of filled containers (2) from said carousel (8), and wherein said ultrasound generating device (30) is arranged along said path (P) in a fixed position adjacent to said output station (7).

10. A method for filling containers (2) comprising the following steps:

- advancing at least one container (2) along a given horizontal path (P);

- feeding a pourable product from above into said container (2) as the container (2) travels along said path (P); and,

- after said container (2) has been filled with the pourable product, applying ultrasonic waves above the level of the pourable product in the container (2) to collapse foam;
characterized in that said ultrasonic waves are emitted at a position arranged below the top of the container (2) advanced along said path (P), and are reflected into said container (2) by a reflecting surface (32) arranged above said container (2).

11. The method as claimed in claim 10, further comprising the step of pressurizing said container (2) before said step of feeding the pourable product and the step of decompressing said container (2) after said step of feeding said pourable product, and wherein said step of applying the ultrasonic waves is carried out after said decompressing step.

Drawing