Process to produce containers out of preforms, in which the preform is inserted in a form-filling station, molded and filled in this station. Gas, which remains in the head space after the end of the filling process, is replaced by a purge gas, and a form-filling machine is provided to produce and to fill containers made of preforms.

An apparatus (1) for producing sterile receptacles (2), comprising: a molding unit (13) for molding parisons (4) starting from granules of thermoplastic material; a stretch-blowing forming unit (3) which receives the parisons (4) from the molding unit (13), the forming unit (3) having a plurality of forming stations (5) in each of which there is a mold (6) and a sterilization device (12) so as to form and sterilize the corresponding parison (4).

A fill assembly sterilization method and system for a blow/fill/seal machine utilizes a closed loop circulation of sterilant containing gas. A typical sterilant is nitrogen dioxide in humidified air. The closed loop includes a shroud that defines a plenum and encloses the fill system. Optionally, at least one high efficiency particulate absorption (HEPA) filter is provided in the closed loop. Sterility assurance level of 10.sup.6 can be achieved by subjecting the fill system to the sterilizing gas for at least 20 minutes at a temperature in the range of about 18 C. to about 30 C. Preferred sterilant gas is humidified air containing about 10 to about 20 milligrams of nitrogen dioxide per liter.

A method of sterilizing a bottle includes steps of: sterilizing bacteria adhering to a preform (1) made of resin by gasifying a sterilizer, discharging a sterilized gas (G) from a nozzle (6) toward a preform, now traveling, so as to adhere to the preform (1); activating the sterilizer adhering to the preform by blasting hot air (P) to the preform; sterilizing the bacteria adhering to the preform, and removing the sterilizer adhering to the preform (1); heating the preform to a temperature suitable for blow-molding treatment; and blow-molding the preform within a mold (4) to mold the preform into a bottle (2), wherein the above steps are performed sequentially in order. According to the above-mentioned steps, the sterilizer does not enter a blow-molding machine.

A fill assembly sterilization system for a blow/fill/seal machine utilizes a closed loop circulation of sterilant containing gas. A typical sterilant is nitrogen dioxide. The closed loop includes a shroud that defines a plenum and encloses the fill system. Optionally, at least one high efficiency particulate absorption (HEPA) filter is provided in the closed loop. Sterility assurance level of 10.sup.6 can be achieved by subjecting the fill system to the sterilizing gas for at least 20 minutes at a temperature in the range of about 18 C. to about 30 C.

A method for fabricating containers wherein a molding apparatus is provided having a plurality of mold segments, each of which has two substantially opposite faces that form a mold cavity when abutted against an opposite face of an adjacent mold segment. A first mold segment is passed through a manipulation zone at an increased speed to open the mold cavity between the first and second mold segments. After a preform is positioned within the mold cavity, a second mold segment is passed through the manipulation zone at an increased speed to abut a face of the first mold segment against an opposite face of the second mold segment. A volume of a liquid is next injected into the preform, expanding the preform and forming the container. These steps are repeated and a container produced during the previous iteration is removed during an extracting step in an extracting manipulation zone.

A method of sterilizing a bottle includes steps of: sterilizing bacteria adhering to a preform made of resin by gasifying a sterilizer, discharging a sterilized gas from a nozzle toward a preform, now traveling, so as to adhere to the preform; activating the sterilizer adhering to the preform by blasting hot air to the preform; sterilizing the bacteria adhering to the preform, and removing the sterilizer adhering to the preform; heating the preform to a temperature suitable for blow-molding treatment; and blow-molding the preform within a mold to mold the preform into a bottle, wherein the above steps are performed sequentially in order. According to the above-mentioned steps, the sterilizer does not enter a blow-molding machine.

A liquid blow molding method molds a bottomed tubular-shaped preform into a liquid containing container. The method includes a nozzle engaging step of engaging a blow nozzle with a mouth of the preform; a molding step of molding the preform into a container of a predetermined shape by supplying a pressurized liquid from a pump into the preform; a suck-back step of sucking back a predetermined volume of liquid out of the container into a supply path; a nozzle closing step of closing the blow nozzle by a sealing body; and a discharge step of discharging a liquid in the supply path by a predetermined volume from a discharge port by operating, after the nozzle closing step, a pump in a positive direction with the discharge port connected to the supply path opened.

An injection device for injecting a pressurized liquid into a preform and forming a container. The injection device including a piston device having a piston body and a piston head arranged to reciprocate in the piston body and to fluidly isolate an inner chamber of the piston device. The piston body having a recess portion defining a location where the piston head is not in liquid tight contact with the piston body such that liquid can flow from the inner chamber to a part of the piston body on an opposite the inner chamber. The injection device being arranged for driving the piston head in the recess portion in a clean-in-place (CIP) configuration.

A method for fabricating containers wherein a molding apparatus is provided having a plurality of mold segments, each of which has two substantially opposite faces that form a mold cavity when abutted against an opposite face of an adjacent mold segment. A first mold segment is passed through a manipulation zone at an increased speed to open the mold cavity between the first and second mold segments. After a preform is positioned within the mold cavity, a second mold segment is passed through the manipulation zone at an increased speed to abut a face of the first mold segment against an opposite face of the second mold segment. A volume of a liquid is next injected into the preform, expanding the preform and forming the container. These steps are repeated and a container produced during the previous iteration is removed during an extracting step in an extracting manipulation zone.