Delivery Unit for an Aseptic Packaging Machine, Aseptic Packaging Machine and Sterilization Method

Abstract

A delivery unit for an aseptic machine for packaging sachets includes at least one nozzle configured to be surrounded, during use, by a wrapping of welded film able to form said sachets. The nozzle includes a product delivery duct which has a distal outlet end configured to deliver a product, and a sterilant delivery duct which has a respective outlet end and is configured to deliver a sterilizing mean.

Claims

1. A method to sterilize a tubular wrapping in a packaging machine during its normal functioning, said packaging machine comprising a delivery unit provided with at least one nozzle configured to feed a product to be packaged, a sterilizing mean and a sterile gas, said method comprising: feeding a film of packaging material along a nozzle of said delivery unit forming a tubular wrapping around said nozzle comprising an upper aperture; feeding a sterilizing mean into said tubular wrapping; said method further comprising the steps of: simultaneously feeding a laminar flow of gas along said nozzle, in the same direction of feed as the film, and outside said tubular wrapping; and making said sterilizing mean flow outside said tubular wrapping through said upper aperture.

2. The method as in claim 1, further including conveying said sterilizing mean along said nozzle and outside said tubular wrapping by means of said laminar flow.

3. The method as in claim 1, further including sucking in the gas and the sterilizing mean downstream of the delivery unit, by means of a suction unit.

4. The method as in claim 1, wherein part of the laminar flow is deflected by a deflector element associated with the nozzle and disposed upstream of the upper aperture of the tubular wrapping, so as not to interfere with the sterilizing mean inside the tubular wrapping.

5. An aseptic machine for packaging sachets starting from a film of packaging material and configured to implement a sterilization method as in claim 1, wherein the machine comprises: a delivery unit at least one nozzle around which a tubular wrapping is created open in its upper part which in turn comprises: a product delivery duct which has an outlet end and is configured to deliver a product, and a sterilant delivery duct which has a respective outlet end, configured to deliver a sterilizing mean, in which and around said outlet ends are enclosed, during use, by said tubular wrapping; and a pressurizer disposed upstream of said delivery unit configured to feed a laminar flow of gas longitudinally to the development axis of the nozzle, so as to convey vapors of the sterilizing mean toward said delivery unit.

6. The aseptic machine as in claim 5, further comprising a suction unit disposed downstream of the delivery unit configured to suck in the laminar flow and the sterilizing mean.

7. The aseptic machine as in claim 5, further comprising first welding means to make, upstream of said outlet end of said sterilant delivery duct, longitudinal welds able to define at least one side of said sachets and further comprising second welding means to make, downstream of said nozzle, transverse welds able to define transverse sides of said sachets so as to seal the latter.

8. The aseptic machine as in claim 5, wherein said delivery unit comprises at least one deflector element, disposed upstream of said outlet end, directly above an upper aperture of said tubular wrapping and allows to protect the upper aperture from external agents, such as a laminar flow of gas, wherein said at least one deflector element is configured to interfere with the flow of said sterilizing mean which exits from said tubular wrapping to allow said sterilizing mean to flow outside of the tubular wrapping without being diluted by said external agents.

9. The aseptic machine as in claim 7, wherein said deflector element is disposed upstream of said first welding means.

10. The aseptic machine as in claim 5, wherein said delivery unit also comprises a sterile delivery duct to deliver a sterile gas, and further comprising a uniforming device associated with said sterile delivery duct configured to make a flow of said sterile gas uniform inside the tubular wrapping.

11. A delivery unit for an aseptic packaging machine comprising at least one nozzle that comprises a product delivery duct which has an outlet end and is configured to deliver a product, and a sterilant delivery duct which has a respective outlet end configured to deliver a sterilizing mean, and around which there is created a tubular wrapping open in its upper part that encloses, during use, said outlet ends, comprising at least one deflector element disposed upstream of said outlet end directly above an upper aperture of said tubular wrapping and allows to protect the upper aperture from external agents, such as a laminar flow of gas, wherein said at least one deflector element is configured to interfere with the flow of said sterilizing mean which exits from said tubular wrapping to allow said sterilizing mean to flow outside of the tubular wrapping without being diluted by said external agents.

12. The delivery unit as in claim 11, wherein the deflector element extends transversely from a development axis of the nozzle.

13. The delivery unit as in claim 11, further comprising a sterile delivery duct to deliver a sterile gas, and further comprising a uniforming device associated with said sterile delivery duct configured to make a flow of said sterile gas uniform inside the tubular wrapping.

Description

ILLUSTRATION OF THE DRAWINGS

[0040] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of some embodiments, given as a non-restrictive example with reference to the attached drawings wherein:

[0041] FIG. 1 is a front view of a delivery unit according to the present invention, in a condition of use;

[0042] FIG. 2 is a longitudinal section view of one embodiment of a delivery unit according to the present invention, taken along plane II-II of FIG. 1;

[0043] FIG. 3 is a longitudinal section view of another embodiment of a delivery unit according to the present invention;

[0044] FIGS. 4, 5, 6 and 7 are schematic cross sections of a portion of different embodiments of a delivery unit according to the present invention; and

[0045] FIG. 8 is a schematic view of an aseptic machine comprising another embodiment of a delivery unit according to the present invention, shown in longitudinal section.

[0046] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can conveniently be combined or incorporated into other embodiments without further clarifications.

DESCRIPTION OF SOME EMBODIMENTS

[0047] We will now refer in detail to the possible embodiments of the invention, of which one or more examples are shown in the attached drawings, by way of a non-limiting illustration. The phraseology and terminology used here is also for the purposes of providing non-limiting examples.

[0048] Referring to FIG. 1, a delivery unit 10 for an aseptic machine 50 for packaging sachets B, hereafter machine 50, comprises at least one nozzle 11.

[0049] According to some embodiments, the at least one nozzle 11 is oblong, that is, it has a longitudinal development, along a development axis A, prevalent with respect to its other sizes.

[0050] The machine 50 is able to move at least one film 20 of material able to form the sachets B around the nozzle 11, and to make it slide along the nozzle 11 in the direction of its longitudinal development by means of suitable means for feeding the film 20 (not shown). In this way, a tubular wrapping 20A is created around the nozzle 11

[0051] In some embodiments, the machine 50 has first welding means 51 (FIG. 1), configured to make longitudinal welds 21, substantially continuous, which join the sides of a film 20. Such longitudinal welds 21 can define at least one side of the different sachets B.

[0052] According to some embodiments, the machine 50 can comprise second welding means 52 which can make, downstream of the nozzle 11, transverse welds 22 which define transverse sides of the different sachets B and which seal them.

[0053] By virtue of this, during use or during the formation of the sachet B, the nozzle 11 can be wrapped, at least partly, by the substantially tubular wrapping 20A of film 20 which slides thereon defined by longitudinal welds 21, made substantially continuously, and closed by the last transverse weld 22A made directly downstream of the nozzle 11. It is noted that the tubular wrapping 20A is open at its upper end, and therefore has an upper aperture 20B (FIGS. 2 and 3).

[0054] In some embodiments, the sachets B can be made with a single film 20 wrapped around itself and around the nozzle 11, during the formation of the sachet B, and welded longitudinally so as to join the two longitudinal sides thereof (FIGS. 6 and 7).

[0055] In some embodiments, the sachets B can be made with two opposite films 20 so as to contain the nozzle 11 between them, during the production of the sachet B, and welded longitudinally so as to join the longitudinal sides of one film 20 with those of the other (FIGS. 3, 4 and 5).

[0056] The film or films 20 are then welded transversely downstream of the nozzle 11, defining the other sides of the sachets B.

[0057] According to some embodiments, the feed of the film 20 around the nozzle 11 occurs continuously and the longitudinal welds 21 are made continuously in accordance with the advance of the film 20.

[0058] In some embodiments, the transverse welds 22 can be made intermittently, in accordance with the advance of the film 20 and with the desired longitudinal size of the sachets B.

[0059] According to some embodiments, the nozzle 11 comprises one or more delivery ducts 12, 13, 14. In particular, the nozzle 11 can comprise a product delivery duct 12, a sterilant delivery duct 13 and a sterile delivery duct 14.

[0060] In some embodiments, the product delivery duct 12 is configured to deliver the product P intended to be contained in the sachets B while the sterilant delivery duct 13 is configured to deliver a sterilizing mean S (FIGS. 2 and 3).

[0061] According to preferred embodiments, the sterilizing mean S is a gaseous mixture of sterilant and air. In particular, the sterilizing mean S can be a gaseous mixture of hydrogen peroxide and air. More preferably, the sterilizing mean S is a hydrogen peroxide vapor.

[0062] In preferred embodiments, the sterile delivery duct 14 is configured to deliver at least one sterile gas G, for example sterile air.

[0063] According to some embodiments, each duct 12, 13, 14 has a respective outlet end 15, 16, 17 disposed along the nozzle 11.

[0064] According to one aspect of the invention, during use, each outlet end 15, 16, 17 comprised in the nozzle 11 can be inside the wrapper 20A of film 20 which slides along the nozzle 11, the wrapper 20A being defined by longitudinal welds 21 and by the last transverse weld 22A made directly downstream of the nozzle 11.

[0065] In preferred embodiments, the outlet end 15 of the product delivery duct 12 coincides with the terminal end of the nozzle 11.

[0066] According to some embodiments, the outlet end 16 of the sterilant delivery duct 13 can be disposed upstream of the outlet end 15 of the product delivery duct 12.

[0067] Advantageously, in this way, the film 20 with which the sachets B are made, which slides along the nozzle 11, comes into contact with the sterilizing mean S before coming into contact with the product P. By virtue of this, packaging sachets B the interior of which has not been sterilized is prevented.

[0068] According to one aspect of the invention, the outlet end 17 of the sterile delivery duct 14 can be positioned, along the longitudinal development of the nozzle 11, between that of the product delivery duct 12 and that of the sterilant delivery duct 13. In particular, the outlet end 17 of the sterile delivery duct 14 can be positioned upstream of that of the product delivery duct 12 and downstream of that of the sterilant delivery duct 13.

[0069] Advantageously, in this way, sterile gas G is delivered between the outlet end 15 of the product delivery duct 12 and the outlet end 16 of the sterilant delivery duct 13. By virtue of this, a volume of sterile gas G is created between the sterilizing mean S and the delivery zone of the product P, which prevents the trapping of sterilizing mean S in the sachet B (FIGS. 2, 3 and 8).

[0070] In some embodiments, the sterile gas G is delivered at a pressure higher than atmospheric pressure.

[0071] In other embodiments, the sterilizing mean S is also delivered at a pressure higher than atmospheric pressure.

[0072] In the example shown, the outlet end 16 of the sterilant delivery duct 13 and the outlet end 17 of the sterile delivery duct 14 are distant from each other by a distance H along the nozzle 11 (FIGS. 1, 2 and 8).

[0073] A person of skill in the art will easily understand that the distance H and the longitudinal feeding speed of the film 20 are sized so as to guarantee a meeting time between the sterilizing mean S and the film 20 which allows a complete sterilization thereof, at least of its surface located inside the wrapper 20A, which will come into contact with the product P to be packaged.

[0074] In an alternative embodiment, not shown in the drawings, in which the three ducts 13, 14, 15 are coaxial, the sterilant delivery duct 13 is equipped with radial delivery means, for example through holes, along a delivery zone of the duct itself around which there is created a zone filled with the sterilizing mean S. In this case, the length H can be the length of the delivery zone, taken longitudinally to the sterilant delivery duct 13, in which the radial delivery means are disposed.

[0075] According to some embodiments, the ducts 12, 13, 14 of the nozzle 11 can be concentric. In particular, with reference to FIGS. 2, 5 and 7, in one embodiment the sterilant delivery duct 13 can partly contain the sterile delivery duct 14 which in turn can partly contain the product delivery duct 12.

[0076] According to preferred embodiments, the ducts 12, 13, 14 of the nozzle 11 are disposed side by side and parallel (FIGS. 1 and 4). This conformation allows to speed up the cleaning operations of the machine 50.

[0077] In other embodiments, two ducts of the nozzle 11 can be disposed concentric and a third can be disposed side by side and parallel to them. One example of this embodiment is shown in FIG. 6, in which the sterilant delivery duct 13 is separated from and parallel to the product delivery duct 12 and the sterile delivery duct 14, which are instead concentric.

[0078] In accordance with some embodiments, the delivery unit 10 also comprises a deflector element 18 associated with the nozzle 11 upstream of the outlet end 16 of the sterilant delivery duct 13 (FIGS. 2 and 3).

[0079] The deflector element 18, advantageously disposed directly above the upper aperture 20B of the tubular wrapping 20A, allows to protect the upper aperture 20B from external elements, such as for example a laminar flow L of air, so as to allow the sterilizing mean S to flow out of the tubular wrapping 20A without being diluted. In addition, the deflector element 18 participates in deflecting the vapor of the sterilizing mean transversely to the development axis A, around the upper aperture 20B.

[0080] Obviously, if the delivery unit 10 comprises a plurality of nozzles 11, each of these is advantageously equipped with a respective deflector element 18 (FIG. 8).

[0081] Preferably, the deflector element 18 has a flat body and is disposed perpendicular to the development axis A (FIG. 2). However, it is possible to provide a deflector element 18 with a substantially truncated cone shape with the external edges oriented downward, as shown in FIG. 3. Obviously, it can also be provided that the external edges are oriented upward.

[0082] It is noted that, preferentially, the delivery unit 10 does not comprise any suction device or unit whatsoever to suck in the sterilizing mean above the tubular wrapping 20A.

[0083] In accordance with other embodiments, the delivery unit 10 also comprises a uniforming device 19 associated with the nozzle 11 in the proximity of the outlet end 17 of the sterile duct 14, and configured make the flow of sterile gas G inside the tubular wrapping 20A uniform, or homogenized. This prevents the creation of preferential routes that lead to a non-uniform dilution of the sterilizing mean S in the sterile gas G inside the tubular wrapping 20A.

[0084] According to some embodiments, the uniforming device is connected to the outlet end 17 of the sterile duct 14 (FIGS. 2 and 3); however, it is also possible to provide that it is integrated with the sterile duct 14, for example by providing a series of lateral through holes distributed over the entire circumference of the duct.

[0085] According to preferred embodiments, the delivery of the sterilizing mean S occurs continuously, in accordance with the feed of the film 20.

[0086] According to preferred embodiments, the delivery of the sterile gas G occurs intermittently, in accordance with the feed of the film 20 and/or with the delivery of the sterilizing mean S. In this way, the sterilizing mean S is momentarily removed from the bottom of the tubular wrapping 20A, so that a dose of product P can be delivered into it and, immediately afterward, the tubular wrapping 20 can be made to advance so as to dispose the dose of product just delivered downstream of the second welding means 52, and thus perform the transverse weld 22A to close a new sachet B.

[0087] It is noted that the delivery of the product P in the bottom of the tubular wrapping 20A causes the thrust of the sterilizing mean S upward, and therefore its exit from the tubular wrapping 20A.

[0088] In preferred embodiments, the delivery of the product P occurs intermittently, in accordance with the modes with which the transverse welds 23 are made. In other embodiments, the delivery of the product P occurs continuously.

[0089] Some embodiments described here also concern an aseptic machine 50 for packaging sachets B comprising at least one delivery unit 10 as described in the present invention.

[0090] The machine 50, schematically shown in FIG. 8, comprises a delivery unit 10 as described above, advantageously disposed so as to have the nozzles 11 oriented vertically with the outlet ends 15, 16, 17 oriented downward.

[0091] According to some embodiments, the machine 50 comprises a pressurizer 53 disposed above the delivery unit 10 and configured to feed a laminar flow L of air, in a vertical or substantially vertical direction and downward (FIG. 8).

[0092] This laminar flow L, which does not enter the tubular wrappings 20A due to the presence of the deflector elements 18, conveys the vapors of the sterilizing mean S downward, and along the external surface of the tubular wrappings 20A, thus creating a micro-environment around such tubular wrappings 20A which contains the sterilizing mean S, and therefore protects the tubular wrappings 20A (FIG. 8).

[0093] In this way, the excess vapors of the sterilizing mean S are exploited to the advantage of the functioning of the filling machine 50.

[0094] We wish to point out that, in this way, the aseptic machine 50, and more particularly its delivery unit 10, allow to effectively and reliably sterilize both the inside and also the outside of the tubular wrappings 20A.

[0095] Below the delivery unit 10, more preferably at the base of the machine 50, there is a suction unit 54 that sucks in the laminar flow L of air together with the conveyed vapors of the sterilizing mean S, in order to expel them outside the machine 50, in a known manner.

[0096] One example of the functioning of the machine 50 will be described in detail below. The following example is described purely by way of illustration and therefore is not to be considered as limiting.

[0097] Referring to FIGS. 1, 2, 3 and 8, during use, one or more films 20 of the material that will form the sachets B slides around at least one nozzle 11.

[0098] By means of the first welding means 51 (FIG. 1) the machine 50 makes longitudinal welds 21 which join the one or more films 20 forming a substantially tubular wrapping 20A that wraps around and contains the nozzle 11. Generally, the longitudinal welds 21 are made upstream of the outlet end 16 of the sterilant delivery duct 13 of the nozzle 11. By means of the second welding means 52 the machine 50 also makes transverse welds 22 which, by transversely closing the wrapping 20A, define the sachets B.

[0099] It is clear that the wrapping 20A advances along the nozzle 11 in accordance with the feed of the film 20. It is also clear that the longitudinal welds 21 are produced continuously in accordance with the advance of the film, in this way, the nozzle 11 is always wrapped and comprised in a wrapping 20A of film 20.

[0100] During use, the sterilant delivery duct 13 delivers a sterilizing mean S inside the wrapping 20A. At the same time, the sterile delivery duct 14 intermittently delivers a sterile gas G under pressure inside the wrapping 20A, downstream of the outlet end 16 of the sterilant delivery duct 13. In this way, a first zone is created in the wrapping 20A in which the advancing film 20 contacts the sterilizing mean S and is consequently sterilized.

[0101] Downstream of this first zone, a second zone is momentarily created which contains the sterile gas G under pressure.

[0102] The sterile gas G in the wrapping 20A serves to purge a corresponding volume of sterilizing mean S so as to be able to deliver a dose of product P to be packaged in the bottom of the tubular wrapping 20A. The delivery of the product P preferably occurs intermittently, in accordance with the delivery of sterile gas G, by means of the product delivery duct 12.

[0103] In addition, the delivery of the product P is carried out above the last transverse weld 22A made. Once the quantity of product P to be packaged has been delivered, another transverse weld 22 is made which closes the sachet B and which defines the new last transverse weld 22A.

[0104] During the production phase of the machine 50, a laminar flow L of air is continuously delivered vertically downward, by means of the pressurizer 53. The laminar flow L which passes through the delivery unit 10 is deflected by the deflector elements 18 so as not to enter inside the tubular wrappings 20A.

[0105] The laminar flow L conveys with it the excess vapors of the sterilizing mean S which come out of the tubular wrappings 20A and makes them lap the external surfaces of the tubular wrappings 20A (FIG. 8). A localized protective micro-environment is thus created which contains the sterilizing mean S.

[0106] The latter is conveyed along the entire delivery unit 10 until it reaches the suction unit 54 at the base of the machine 50, where the vapors of the sterilizing mean S and the air of the laminar flow L are sucked in and fed to the outside of the machine, in a known manner.

[0107] It is clear that modifications and/or additions of parts or steps may be made to the delivery unit 10, to the machine 50 and to the sterilization method as described heretofore, without departing from the field and scope of the present invention as defined by the claims.

[0108] In the following claims, the sole purpose of the references in brackets is to facilitate reading: they must not be considered as restrictive factors with regard to the field of protection claimed in the specific claims.