One embodiment of the present invention provides an apparatus for processing sealed plastic containers having a first headspace pressure. The apparatus may include: an open entry port or tunnel for continuously receiving containers; a sanitizer configured to sanitize outside surfaces of the received containers; a perforator configured to perforate or open a cap or seal of the containers within the apparatus; a sealer configured to seal the perforation or opening formed in the cap or seal of the containers; an open exit port of tunnel for continuously exiting the processed containers; and a conveyor system configured to transporting or convey the containers from the open entry port or tunnel, through and within the apparatus, to the open exit port or tunnel and away from the sanitized environment of the apparatus. The apparatus may be further configured to maintain a sanitized environment within the apparatus, perforator, and/or sealer.

One embodiment of the present invention provides an apparatus for processing sealed plastic containers having a first headspace pressure. The apparatus may include: an open entry port or tunnel for continuously receiving containers; a sanitizer configured to sanitize outside surfaces of the received containers; a perforator configured to perforate or open a cap or seal of the containers within the apparatus; a sealer configured to seal the perforation or opening formed in the cap or seal of the containers; an open exit port of tunnel for continuously exiting the processed containers; and a conveyor system configured to transporting or convey the containers from the open entry port or tunnel, through and within the apparatus, to the open exit port or tunnel and away from the sanitized environment of the apparatus. The apparatus may be further configured to maintain a sanitized environment within the apparatus, perforator, and/or sealer.

An apparatus for hot or warm filling comprising a compression machine configured to apply an axial compression force to a collapsible thermoplastic container for liquids. The compression machine includes a lower body having a surface designed to be a resting surface for the base of the container; at least one upper body designed to contact a portion of the container above the peripheral groove, so that the container can be held in an upright position by the at least one lower body and the at least one upper body; actuating means for actuating the at least one lower body and/or the at least one upper body in order to apply said axial compression force, acting along a direction parallel to the longitudinal axis of the container, in order to make the proximal straight side to come into contact with the distal straight side, thus reducing the internal volume of the container.

An apparatus for hot or warm filling comprising a compression machine configured to apply an axial compression force to a collapsible thermoplastic container for liquids. The compression machine includes a lower body having a surface designed to be a resting surface for the base of the container; at least one upper body designed to contact a portion of the container above the peripheral groove, so that the container can be held in an upright position by the at least one lower body and the at least one upper body; actuating means for actuating the at least one lower body and/or the at least one upper body in order to apply said axial compression force, acting along a direction parallel to the longitudinal axis of the container, in order to make the proximal straight side to come into contact with the distal straight side, thus reducing the internal volume of the container.

A method of forming a container and filling the container with a product. The method includes heat-set blow molding the container from a preform and hot-filling the container with the product such that the product occupies about 95% or more of a total interior volume of the container. A headspace volume is defined between a top fill line of the product and a brim of the container. The headspace volume is less than about 5% of the total interior volume of the container. The container is capped and allowed to cool. The container is configured to shrink during cooling such that the total interior volume decreases by about 0.5% to 1.5% during cooling. A base of the container is displaced after hot-filling and capping to reduce the total interior volume by less than about an additional 0.5% to 4%. The hot-filling, capping, cooling, and displacing of the base creates a pressure change within the container.

In some embodiments, a sealing and pressure dosing apparatus may be provided. The sealing and pressure dosing apparatus may include a sealing machine having one or more of a driven turret, a sealing head, a pressure sealing member, and a pressure sealing chamber. The sealing and pressure dosing apparatus may also include a pressure dosing system which may be integrated with the sealing machine.

In some embodiments, a sealing and pressure dosing apparatus may be provided. The sealing and pressure dosing apparatus may include a sealing machine having one or more of a driven turret, a sealing head, a pressure sealing member, and a pressure sealing chamber. The sealing and pressure dosing apparatus may also include a pressure dosing system which may be integrated with the sealing machine.

An automated, unmanned continuous system (200) for packaging flowable food products at elevated temperatures and pressures includes an upstream thermal processing station (202) to heat the food products and direct the heated food products to a pressurized unmanned filling station (204), whereat containers (242) are filled with the heated food products within a pressurized housing (232), and then transported to a pressurized and unmanned sealing station (206) where the containers are sealed with a lid or cover (283) within a pressurized housing (282). Thereafter, the filled and sealed containers (242) are routed from the pressurized housing (282) through a pressurized transfer tube or passageway (208) for further processing at a downstream thermal processing station (210).

One embodiment of the present invention provides a method for processing plastic containers within an open aseptic converter chamber comprising a sanitized environment, a supply line, a sanitizer device, a perforator device, a sealing device, and a conveyer. During operation, the method includes: providing and filling a container with heated or heatable liquid including water; sealing the container with a seal or cap; cooling the container to create a first headspace pressure; enclosing the container within the chamber; creating an opening in the seal or cap within a sanitized environment of the perforator device; increasing the first headspace pressure to a second headspace pressure by introduction of a sanitized fluid; resealing the container within a sanitized environment of the sealing device; and, transporting or conveying the sealed container away from the chamber.

One embodiment of the present invention provides a method for processing plastic containers within an open aseptic converter chamber comprising a sanitized environment, a supply line, a sanitizer device, a perforator device, a sealing device, and a conveyer. During operation, the method includes: providing and filling a container with heated or heatable liquid including water; sealing the container with a seal or cap; cooling the container to create a first headspace pressure; enclosing the container within the chamber; creating an opening in the seal or cap within a sanitized environment of the perforator device; increasing the first headspace pressure to a second headspace pressure by introduction of a sanitized fluid; resealing the container within a sanitized environment of the sealing device; and, transporting or conveying the sealed container away from the chamber.