BOTTLING PROCESS AND PLANT FOR BOTTLING A CONTAINER FOR PUMPABLE FOOD PRODUCTS

Abstract

 A bottling process for bottling a container (2) for pumpable food products, comprising the following steps:
introducing at least one first UV-C lamp (11) inside the container (2);
radiating the inner surface with the first UV-C lamp (11) for a predefined time period;
filling the container (2), with the product at a temperature comprised between 75 °C and 90 °C, so as to abate the residual bacterial load resulting from the radiating step, in which the product is subjected to a heat treatment for cooking without further successive heatings;
supplying a closing element (31) for closing the container (2) and sterilising by radiation the inside of the closing element (31) during the supplying step;
applying the sterilised closing element (31) to the container (2).

Description

[0001] The present invention relates to a bottling process and plant for bottling a container for pumpable food products.

[0002] Pumpable food products are herein intended as liquid and semi-liquid products with and without solid suspensions (i.e., pieces), which nevertheless have properties which allow pumping.

[0003] This process can be used with any pumpable food product, but is particularly suitable for fluids such as tomato purees or more generally acidic products, as these require more severe bacterial load abatements than dairy or centrifuged products, fruit extracts or smoothies.

[0004] Traditionally, in the field of tomato purees, the most commonly used filling line consists of sanitising a glass container in two steps:

• hot filling, i.e., filling the container with the product at temperatures comprised between 80 °C and 90 °C (or even higher, depending on the composition of the product or the line) and subsequent capping;
• passage in a pasteurisation tunnel in which initially a hot rain of water or steam at a constant temperature of about 90-95 °C hits the already-capped container for a variable period of time depending on the composition recipe of the product and performs pasteurisation; subsequently a cold rain of water cools it, through zones at decreasing temperatures to avoid the cracking of the glass.

[0005] However, this "traditional" filling line has a number of disadvantages:

• significant loss of the product's organoleptic properties due to the inevitable "recooking" of the product inside the container during pasteurisation;
• loss of shine of the product's colour caused by the pasteurisation process itself, thus making the product less appealing to the consumer;
• impossibility of using PET containers, as these would not withstand long-lasting heat in the pasteurisation tunnel;
• high post-filling vacuum values;
• high variable costs, for example for the use of steam and hot water;
• high installation and management costs due to the presence of the pasteurisation tunnel.

[0006] An alternative solution to the "traditional" one is the aseptic filling line, which involves the complete sanitisation of the container within structures with very rigid atmosphere control, to avoid potential re-contamination. The filling of the product, due to the certainty of having a sterile container, usually takes place "cold", therefore at temperatures very close to room temperature.

[0007] The abatement of the bacterial load inside the container in the aseptic filling line takes place by washing the container with aqueous solutions containing, for example, surfactants, antibacterial agents, microbial agents and/or antiseptic agents. Thereafter, the container exposed to such aggressive chemicals is rinsed one or more times in an attempt to remove any chemical residues.

[0008] This solution overcomes some disadvantages of the so-called traditional line, but mainly has two major drawbacks: a very high cost of the plant and maintenance/certification cost thereof, which cost is difficult to sustain for many companies, and entails the need for very high sales volumes to justify the choice of this filling line, and the use of chemicals for the bacterial load abatement. In fact, it is necessary, also from the consumer's point of view, that the container is practically free of every single drop of chemical residue before filling. This involves a great deal of time and can be particularly complicated with some container geometries which increase the possibility of trapping residual fluids, especially if the contaminants have viscous or highly adhesive properties. Furthermore, this container sanitising method generates environmental pollution problems related to the disposal of chemicals.

[0009] Recently, a known solution proposed by document EP2816002 provides for the sterilisation of the outside and inside of the container by radiation with UV-C lamps as part of an aseptic filling line. This solution overcomes the problems related to container sterilisation with chemicals, but introduces problems related to the high energy consumption in the use of radiation in order to completely sterilise (also outside) the container and of plant complexity (therefore costs) due to the use of robotic arms and a completely aseptic environment.

[0010] In this context, the technical task underpinning the present invention is to propose a bottling process and plant for bottling a container for pumpable food products, which obviate the drawbacks of the above-cited prior art.

[0011] In particular, an object of the present invention is to propose a bottling process for bottling a container for pumpable food products which preserves the organoleptic properties of the product.

[0012] A further object of the present invention is to propose a bottling process for bottling a container for pumpable food products which results in lower energy consumption than the known solutions.

[0013] Another object of the present invention is to provide a bottling plant for bottling a container for pumpable food products, in accordance with the process proposed herein, with a simplified structure and reduced overall dimensions compared to the known solutions.

[0014] The defined technical task and the specified objects are substantially achieved by a bottling process for bottling a container for pumpable food products, comprising the following steps:

• introducing at least one first UV-C lamp inside the container;
• radiating the inner surface with the first UV-C lamp for a predefined period of time so as to reduce the bacterial load in a controlled way;
• filling the container with a product at a temperature comprised between 75 °C and 90 °C, so as to abate the residual bacterial load resulting from the radiating step for radiating the inner surface;
• supplying a closing element for closing the container;
• sterilising at least the inside of the closing element by radiation with at least one second UV-C lamp during the supplying step;
• applying the sterilised closing element to the filled container.

[0015] The product is subjected to a single heat treatment without further heatings so as to conserve the organoleptic properties thereof.

[0016] In accordance with one aspect of the invention, the product is not subjected to further heat treatments following cooking.

[0017] Preferably, there is a treating step for treating the inside of the container by blowing air, which takes place before the step of filling the container.

[0018] In accordance with one aspect of the invention, the steps of treating the inside of the container, introducing at least one first UV-C lamp and radiating the inner surface take place in a same treatment station. Preferably, the treating step for treating the inside of the container comprises the following substeps:

picking up the container;

possible first overturning or movement of the container to bring it to a substantially vertical position with the mouth facing downwards;

blowing air inside the overturned container;

second overturning of the container to bring it to a substantially vertical position with the mouth facing upwards.

[0019] According to one aspect of the invention, the steps of introducing at least one first UV-C lamp and radiating the inner surface take place subsequently to the blowing step for blowing air inside the overturned container and prior to the second overturning step for overturning the container. The first UV-C lamp is inserted from below inside the overturned container.

[0020] In accordance with one aspect of the invention, the process comprises a heat conditioning step for heat conditioning the container at least partially contemporaneously to the radiating step for radiating the inner surface. The defined technical task and the specified objects are substantially achieved by a bottling plant for bottling a container for pumpable food products, in accordance with the process, comprising:

• a treatment station for treating the container comprising at least one first UV-C lamp suitable for radiating the inner surface of the container;
• a filling station for filling the container, located downstream of the treatment station;
• a closing station for closing the container, located downstream of the filling station;
• a supply line for supplying a closing element for closing the container to the closing station comprising at least one second UV-C lamp suitable for sterilising the closing element during the supply.

[0021] Preferably, the treatment station further comprises blower nozzles configured to blow air inside the container.

[0022] In accordance with one aspect of the invention, the treatment station further comprises a heat conditioning system operatively active on the container in order to condition the temperature thereof.

[0023] In accordance with one aspect of the invention, the treatment station further comprises movement means configured to overturn the container. Preferably, the movement means comprises a guide conformed so that the container, during the advancement thereon, is positioned with the head thereof facing downwards.

[0024] According to one aspect of the invention, the treatment station, the filling station and the closing station are arranged in a controlled-atmosphere environment, i.e., a volume separated from the outside environment so as to limit the inlet of contaminants from the outside environment.

[0025] Further characteristics and advantages of the present invention will become more apparent from the indicative, and thus non-limiting, description of a preferred, but not exclusive, embodiment of a bottling process and plant for bottling a container for pumpable food products, as illustrated in the accompanying drawings, in which:

• figure 1 shows a bottling plant for bottling a container for pumpable food products, according to the present invention, in schematic plan;
• figure 2 shows a first UV-C lamp inserted inside an overturned container, in front view;
• figure 3 shows an embodiment of a supply line for supplying a closing element of the bottling plant of figure 1, in perspective view.

[0026] The bottling process for bottling a container 2 for pumpable food products, according to the present invention, is described below.

[0027] Preferably, the container 2 is a bottle or a vase. Preferably, the container 2 is made of glass or plastic material, for example, PET.

[0028] The process comprises introducing at least one first UV-C lamp 11 inside a container 2 and subsequently radiating the inner surface for a predefined period of time so as to reduce the bacterial load in a controlled way. In particular, the term "in a controlled way" means that the radiation of the inside of the container 2 with the first UV-C lamp 11 is used to partially abate the bacterial load and not to completely sanitise the container 2. The percentage of bacterial load abated with the radiating step depends on the type of product and the composition thereof.

[0029] The following are, by way of example, some experimental tests which show the abatement (with Logarithmic base) of the contamination by Aspergillus Niger both in the neck (COL) and in the body (COR) following radiation by means of UV-C lamp. As can be noted, the abatement obtained with this process is partial.

Contamination point	Treatment time(s)	Average NO (cfu/spot)	Average NO Log	Average Nf (cfu/spot)	Average Nf Log	LCR (Average NO Log - Average Nf Log)
COL-S	9	3.90E+04	4.59	1.31E+03	3.12	1.48
COL-S	14	3.90E+04	4.59	4.03E+02	2.61	1.99
COR-S	9	3.00E+04	4.48	4.34E+02	2.64	1.84
COR-S	14	3.00E+04	4.48	5.00E+01	1.70	2.78

[0030] Preferably, the process further comprises a heat conditioning step for heat conditioning the container 2 at least partially contemporaneously to the radiating step for radiating the inner surface. Preferably, the heat conditioning step takes place contemporaneously to the radiating step for radiating the inner surface.

[0031] In particular, the heat conditioning step comprises a cooling of the container 2. This cooling is of significant importance if the radiated container 2 is made of plastic material. In fact, the heat emitted by the first UV-C lamp 11 could result in unpleasant deformations of the container 2. Subsequently, the process comprises a filling of the container 2 with the hot product. The term "hot" herein is intended as a temperature comprised between 75 °C and 90 °C, preferably between 80 °C and 85 °C. This parameter is essential because it is a value which varies as a function of the composition of the product and must ensure the total abatement of the residual bacterial load following the exposure to the UV-C rays. In other words, the parameters for abating the bacterial load by radiation with UV-C rays and the temperature of the product for filling are chosen so as to ensure the sanitisation of the container 2 at the end of the filling process. Advantageously, the product is subjected to a single heat treatment for cooking without further successive heatings. In other words, the product is cooked, reaching temperatures comprised between 90 °C and 115 °C, and the temperature thereof is controlled so that, also considering the temperature decrease due to the transport to be poured into the container 2, it does not fall below the predefined temperature value for the "hot" filling, i.e., filling the container 2 with the hot product, as described above. In other words, it is understood that, with appropriate temperature control systems, the controlled temperature reduction of the product, from the cooking step (highest) to the filling step (lowest), does not require further increases in heat. Therefore, the product is not subjected to rises in heat or sudden cooling below a temperature suitable for hot filling. This optimally preserves the organoleptic properties of the product itself. Successive heating herein means that the product is not subjected to temperature increases after cooking until the end of the production process, therefore even after the filling step.

[0032] The process further comprises a step of supplying a closing element 31 for closing the container 2, a step of sterilising at least the inside of the closing element 31 by radiating with at least one second UV-C lamp 41 during said supplying step and a capping step in which the sterilised closing element 31 is applied to the already filled container 2.

[0033] Preferably, the process further comprises a treatment of the inside of the container 2 to be filled by blowing air.

[0034] Preferably, such treatment takes place before the step of introducing one UV-C lamp 11 inside the container 2.

[0035] In fact, the container 2 can be produced in a different factory and transported in uncontrolled contamination conditions. Alternatively, the container 2 can be produced in the same plant, but the transport from the production unit and to the bottling unit takes place under uncontrolled contamination conditions.

[0036] Therefore, the container 2 is potentially dirty and a treatment is provided by blowing air inside it in order to remove any dirt.

[0037] According to one embodiment, this treatment step comprises the following steps:

• picking up the container 2;
• if the container 2 is not already in a substantially vertical position with the mouth downwards, first overturning or movement of the container 2 to that position;
• blowing air inside the overturned container 2;
• second overturning of the container 2 to bring it to a substantially vertical position with the mouth facing upwards.

[0038] In this way, following the blowing of air, any dirt residues fall out of the container 2 by gravity, as well as internal overpressure.

[0039] Preferably, the step of treating the inside of the container 2, the step of introducing at least one first UV-C lamp 11 inside the container 2 and the step of radiating the inner surface take place in a same treatment station 10.

[0040] Preferably, the step of introducing at least one first UV-C lamp 11 inside the container 2 and the step of radiating the inner surface take place after the air blowing step inside the overturned container 2 and before the second overturning step of the container 2. In other words, such steps take place when the container 2 is still overturned, with the head thereof facing downwards.

[0041] According to another embodiment, this treatment takes place at least partially contemporaneously to the step of introducing at least one first UV-C lamp 11 and the step of radiating the inner surface of the container 2. Preferably, such treatment takes place contemporaneously to the step of introducing at least one first UV-C lamp 11 and the step of radiating the inner surface of the container 2.

[0042] In this case, the air used for the treatment of the inside of the container 2 is also used for the cooling of the container 2 during the exposure to the UV-C rays.

[0043] The bottling plant 1 for bottling a container 2 for pumpable food products in accordance with this process, according to the present invention, is described below.

[0044] The plant 1 comprises a treatment station 10 of the container 2. In this station 10 at least one first UV-C lamp 11 is installed, configured for radiating the inner surface of the container 2. Preferably, the first UV-C lamp 11 is conformed so as to be able to be inserted inside the container 2 and uniformly radiate the inner surface.

[0045] This first UV-C lamp 11 is a known and commercially available device. By way of example, the first lamp 11 used during the experiment is of the medium-pressure, multi-frequency, 400 W type with a single terminal. Preferably, blower nozzles configured to blow air inside the container 2 so as to remove any dirt are also installed in the treatment station 10.

[0046] In one embodiment, the treatment station 10 further comprises movement means configured to overturn the container 2. In other words, the container 2 is vertical with the mouth facing upwards, as in a common situation of use, and is rotated substantially 180° so that it is vertical, but with the mouth facing downwards.

[0047] In such an embodiment, the blower nozzles are installed in the treatment station 10 to blow air from below.

[0048] Preferably, also the at least one first UV-C lamp 11 is installed so as to be inserted from below inside the overturned container 2.

[0049] Preferably, the movement means comprises a guide which has a trend so as to position the container 2 with the head thereof facing downwards during the advancement thereon. This guide is known as a twister guide. Thus, the container 2 is subjected to the blowing of air by the blower nozzles while it is overturned. In this way, the blown dirt falls out of the container 2 by gravity.

[0050] In an alternative embodiment, the movement means comprises a robotic arm.

[0051] In a further embodiment, the movement means comprises gripping elements, i.e., grippers.

[0052] Advantageously, the treatment station 10 further comprises a heat conditioning system operatively active on the container 2 to condition the temperature thereof during the exposure to the UV-C rays. In particular, said system is operatively active to impose a cooling on the container 2.

[0053] In accordance with one embodiment, the blower nozzles are also configured to cool the container 2 radiated (and thus heated) by the at least one first UV-C lamp 11.

[0054] The plant 1 comprises a filling station 20 for filling the container 2, located downstream of the treatment station 10 and a closing station 30 for closing the container 2, located downstream of the filling station 20.

[0055] In the embodiment described and illustrated herein, the treatment station 10, the filling station 20 and the closing station 30 have an in-line operation. A conveyor belt 50 transports the container 2 from the treatment station 10 to the closing station 30.

[0056] In an alternative embodiment, the treatment station 10, the filling station 20 and the closing station 30 are of the rotating carousel type.

[0057] The plant 1 further comprises a supply line 40 for supplying a closing element 31 for closing the container 2 to said closing station 30. At least one second UV-C lamp 41 configured to sterilise the closing element 31 during the supply to the closing station 30 is installed along the line 40. Preferably, the supply line 40 comprises at least one guide 42 within which the closing element 31 slides until the closing station 30.

[0058] Preferably, the second UV-C lamp 41 is installed along the line 40 so as to be in proximity to, i.e., near, the closing element 31 to be sterilised. Preferably, the second UV-C lamp is flat.

[0059] Advantageously, the UV-C lamps (11, 41) installed on the plant 1 are controlled by an autonomous electronic system configured to reduce power in times of non-use.

[0060] Preferably, the treatment station 10, the filling station 20 and the closing station 30 are arranged in a controlled-atmosphere environment.

[0061] Controlled-atmosphere environment is intended as a volume which is separated from the (dirty) outside environment by means of a physical separation which has the purpose of limiting the inlet of contaminants from the outside environment. In particular, the physical separation need not necessarily be sealed. For example, the controlled-atmosphere environment is maintained at a preset overpressure value. Preferably, microfiltered air flows from special devices are used to generate such overpressure. The purpose of preparing the controlled-atmosphere environment is to limit the re-contamination of the containers in the transfer from one station to the next.

[0062] The features of a bottling process and plant for bottling a container for pumpable food products according to the present invention emerge clearly from the above description, as do the advantages.

[0063] In particular, the organoleptic properties of the product are preserved by the use, in place of the pasteuriser, of UV-C lamps in combination with the hot filling to sanitise the container, thus rendering the heating after the filling typical of the pasteurisation step unnecessary. Starting from the cooking step, the product will gradually reduce the temperature thereof as it continues in the filling line and will no longer be heated.

[0064] In addition, the sanitising of the container entrusted not only to the UV-C lamps, but even to hot filling, also entails a significant reduction in energy consumption and costs. In fact, the radiating with UV-C lamps is not used for the total sterilisation of the container, so it is sufficient to use UV-C lamps with lower power compared to the known solutions and a shorter radiating time, which consequently leads to a reduction in consumption. Moreover, the use of the heat of the cooked product to abate the residual bacterial load forms an energy recovery within the process which further reduces consumption.

[0065] Furthermore, the use of radiation instead of chemicals for sterilisation normally results in a reduction in sanitation times, in addition to overcoming all problems related to disposal.

[0066] Furthermore, the sanitisation by radiation instead of pasteurisation also allows the adoption of 100% recyclable single-layer PET plastic containers, without however entailing the high costs of aseptic filling lines, the only option currently available to use containers of this material. Finally, the absence of the pasteurisation tunnel leads to a significant reduction in consumption and size, as well as in the cost of acquiring a traditional pasteurisation tunnel.

[0067] With regard to overall size, the present invention also provides for the possibility of use in pre-existing systems with quite limited modifications. In fact, for example, it is possible to install UV-C lamps in existing treatment stations, thus reducing the dimensions necessary for a dedicated sterilisation station.

Claims

1. A bottling process for bottling a container (2) for pumpable food products, comprising the following steps:

introducing at least one first UV-C lamp (11) inside the container (2);

radiating the inner surface with said at least one first UV-C lamp (11) for a predefined time period so as to reduce the bacterial load in a controlled way;

filling the container (2), with a product at a temperature comprised between 75 °C and 90 °C, so as to abate the residual bacterial load resulting from the radiating step for radiating the inner surface,

wherein said product is subjected to a single heat treatment for cooking without further successive heatings so as to conserve the organoleptic properties thereof;

supplying a closing element (31) for closing the container (2);

sterilising at least the inside of the closing element (31) by radiation with at least one second UV-C lamp (41) during the supplying step;

applying the sterilised closing element (31) to the filled container (2).

2. The process according to claim 1, wherein the product is not subjected to further heat treatments following cooking.

3. The process according to claim 1 or 2, further comprising a treating step for treating the inside of the container (2) by blowing air, said treating step preceding the filling step for filling the container (2).

4. The process according to claim 3, wherein said steps of treating the inside of the container (2), of introducing at least one first UV-C lamp (11) and of radiating the inner surface take place in a same treatment station (10).

5. The process according to claim 3 or 4, wherein the treating step for treating the inside of the container (2) comprises the following substeps:

picking up the container (2);

possible first overturning or movement of the container (2) to bring it to a substantially vertical position with the mouth facing downwards;

blowing air inside the overturned container (2);

second overturning of the container (2) to bring it to a substantially vertical position with the mouth facing upwards.

6. The process according to claim 5, wherein the steps of introducing at least one first UV-C lamp (11) and of radiating the inner surface take place subsequently to the blowing step for blowing air inside the overturned container (2) and prior to the second overturning step for overturning the container (2), said at least one first UV-C lamp (11) being inserted from below inside the overturned container (2).

7. The process according to any one of the preceding claims, further comprising a heat conditioning step for heat conditioning the container (2) at least partially contemporaneously to the radiating step for radiating the inner surface.

8. A bottling plant (1) for bottling a container (2) for pumpable food products according to the process according to claims 1 to 7, comprising:

a treatment station (10) for treating the container (2) comprising at least one first UV-C lamp (11) suitable for radiating the inner surface of the container (2);

a filling station (20) for filling the container (2), located downstream of the treatment station (10);

a closing station (30) for closing the container (2), located downstream of the filling station (20);

a supply line (40) for supplying a closing element (31) for closing the container (2) to said closing station (30), comprising at least one second UV-C lamp (41) configured to sterilise said closing element (31) during the supply.

9. The plant (1) according to claim 8, wherein said treatment station (10) further comprises blower nozzles configured to blow air inside the container (2).

10. The plant (1) according to claim 8 or 9, wherein said treatment station (10) further comprises a heat treatment system operatively active on the container (2) in order to condition the temperature thereof.

11. The plant (1) according to any one of claims 8 to 10, wherein said treatment station (10) further comprises movement means configured to overturn the container (2).

12. The plant (1) according to claim 11, wherein said movement means comprises a guide conformed in such a way that the container (2), during the advancement thereon, is positioned with the head thereof facing downwards.

13. The plant (1) according to any one of claims 8 to 12, wherein said treatment station (10), said filling station (20) and said closing station (30) are arranged in a controlled-atmosphere environment, i.e. a volume separated from the outside environment so as to limit the inlet of contaminants from the outside environment.

Drawing