Hybrid method for processing containers

Abstract

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.

Claims

1. A method for processing plastic containers comprising: i. providing an empty container suitable for hot-filling; ii. filling the empty container with heated or heatable liquid including water; iii. sealing the filled container with a seal or cap to close the container; iv. cooling the liquid in the sealed container to create a first headspace pressure within the container; v. enclosing the cooled and sealed container within an open aseptic converter chamber, wherein the aseptic converter chamber comprises: a sanitized environment within the aseptic converter chamber; a supply line configured to receive gases, the sanitized environment within the aseptic converter chamber being maintained by introduction of the gases at a raised ambient pressure through the supply line; a sanitizer device configured to clean outside surfaces of the containers thereby maintaining the sanitization of the containers within the aseptic converter chamber; a perforator device configured to perforate or open the cap or seal of the container within the aseptic converter chamber; a sealing device configured to seal the opening or perforation within the aseptic converter chamber; and a conveyor system configured to transport or convey multiple containers through and within the aseptic converter chamber; vi. creating an opening in the seal or cap of the container within a sanitized environment of the perforator device for creating an opening in the seal or cap; vii. increasing the first headspace pressure to a second headspace pressure within the container by introducing a sanitized fluid to a headspace of the container; viii. resealing the container within a sanitized environment of the sealing or device; ix. transporting or conveying the sealed container away from the sanitized environment of the aseptic converter chamber.

2. The method of claim 1, wherein the sanitized environment of the perforator device is shared with the sanitized environment of the aseptic converter chamber.

3. The method of claim 2, wherein the second headspace pressure is between 0.0003 psi and 0.001 psi.

4. The method claim 1, wherein the sanitized environment of the perforator device comprises an additional supply line providing an additional sanitized fluid.

5. The method of claim 4, wherein the additional sanitized fluid includes a sweetener.

6. The method of claim 4, wherein the additional sanitized fluid includes flavour ingredients.

7. The method of claim 4, wherein the additional sanitized fluid includes nitrogen.

8. The method of claim 1, wherein the heated or heatable liquid includes a sweetener.

9. The method of claim 8, wherein the heated or heatable liquid includes flavour ingredients.

10. The method of claim 1, wherein the sanitized environment of the sealing device is shared with the sanitized environment of the aseptic converter chamber.

11. The method of claim 10, wherein the sanitized environment of the aseptic converter chamber is shared with both the sanitized environment of the perforate or means and the sanitized environment of the sealing device.

12. The method of claim 1, wherein the sanitized environment of the sealing device comprises an additional supply line providing an additional sanitized or pressurized fluid.

13. The method of claim 12, wherein the additional sanitized fluid includes a sweetener.

14. The method of claim 12, wherein the additional sanitized fluid includes flavour ingredients.

15. The method of claim 12, wherein the sealing device provides a pressure seal against a surface of the sealed or capped container and the additional sanitized fluid pressurizes the container creating a headspace pressure between about 0.001 psi to 15 psi.

16. The method of claim 15, wherein the sealing device increases the second headspace pressure to a third headspace pressure.

17. The method of claim 12, wherein the perforat or device and/or the sealing device are pressurized and sanitized within a sealed environment increasing the headspace pressure above 0.001 psi.

18. The method of claim 1, including transporting or conveying containers from an entry port or tunnel of the aseptic converter chamber, through and within the sanitize device, the perforat or device, and the sealing device, to an exit port.

19. The method of claim 1, wherein the step of creating an opening in the cap or seal includes piercing the cap by means of mechanical puncture force.

20. The method of claim 1, wherein the for perforat or device includes a rotary device.

21. The method of claim 1, wherein the sealing device includes a rotary device.

22. The method of claim 1, including blow-moulding the container.

23. The method of claim 1, including initiating cleaning or sanitizing of the container before the container enters the aseptic converter chamber.

24. The method of claim 1, wherein the sanitizatizer device comprises at least one of a steam tunnel, hydrogen peroxide spray or similar disinfectant or gaseous sterilizing agent, flash heat or pasteurization, or ultraviolet light or radiation.

25. The method of claim 1, wherein the gases received through the supply line includes a sanitized, high-efficiency particulate arrestance (HEPA) filtered or pressurized fluid including nitrogen.

Description

DRAWING DESCRIPTIONS

(1) FIG. 1 A simplified production line direction (1). An empty container (2) is filled with a hot beverage (31) and the container is capped or sealed (11). A headspace (5) exists above the fluid level (4) of the filled liquid. Cooling fluid (13b) is sprayed over the outer surface or by similar cooling means producing a cooled container (12) with a vacuum (20). The Entry port (108) of the Aseptic Line Converter Chamber (104) wherein the outside surfaces of the container may be cleaned (15) by Sterilization or Pasteurization Cleaning Means (104b) emitted from a Sterilization Device (104c). When verifiably cleaned the container engages with a Perforator Means or Device (105) and the cap or seal may be perforated or otherwise opened (8). Following the step of repressuring the headspace, the container is conveyed or otherwise transported (107) to a Sealing Means or Device (106) and the container may then be resealed (17). The container is now vacuum modified (18) upon exiting through the Exit port (109) to be labeled (19).

(2) FIG. 2 shows much the same method as disclosed in FIG. 1. A recently hot-filled and capped container (11) is inverted (102), then reinverted (102a). The container then enters a standard cooling device (13) where cooling fluids (13b) are sprayed over the outside surface of the containers from outlets (13a). Once cooled the containers may be conveyed or moved to enter the aseptic environment (111) of the Aseptic Converter Chamber (104). The Sanitizer device (104c) dispenses Sanitization Means (104b) over the outer surfaces of the containers. In this embodiment they reach the Perforator means or device (105) then engages with a Sealing means or device (106).

(3) FIG. 3 shows the Aseptic Converter Chamber (104) comprising an entry port or tunnel (108) and an exit port or tunnel (109). A supply line (110) causing a slightly raised ambient pressure (112) to escape via the entry or exit ports towards the ambient pressure (113). The converter Chamber comprises a Sterilizing means or device (104c), in this embodiment emitting steam as a sterilizing means (104b). The Perforator means or device (105) will create an opening in the container. Following this the container is moved to a Sealing means or device (106).

(4) FIG. 4 A Perforator means or device (105) is shown in a simplified production line direction (1). A filled container has a cap or seal (3) enclosing a previously pasteurized headspace (5). Included is a separate Secondary fluid supply line (40) for introduction of a different fluid mixture than found within the Converter Chamber. A Perforator mechanism (6) may pierce the cap and the fluid level within the container lowers (4a). In this embodiment the Perforator mechanism then retracts leaving a hole (62) in the now perforated cap (8).

(5) FIG. 5 shows a Perforator means or device (105) of the present disclosure. An additional Primary fluid supply line (39). There is a Perforator mechanism (6) produces a lower fluid level (4a). A Primary fluid supply line (39) thus providing for an aseptic fluid liquid (9). The Primary aseptic fluid supply line (39) will provide the aforementioned aseptic fluid to the system and onto into container. In this embodiment the fluid level within the container lowers (4a) as the Perforator mechanism pierces the container cap. The Perforator mechanism then retracts leaving a hole (62) in the now perforated cap (8).

(6) FIG. 6 shows an embodiment much like FIG. 5 however the cap or seal (3) has a raised or otherwise manipulated portion of geometry (3a) located where the Perforator mechanism (6) is designed to perforate the cap. The Perforator mechanism has additional outlets or openings (6b). A perforated cap (8). The transfer of ambient aseptic fluid (7). The Primary fluid supply line (39) which enters the Perforator means or device (105) from a previously aseptically sanitized source.

(7) FIG. 7 shows the diameter of the mechanism (6) above the holes (6b) may be increase. The container headspace (5) is neutralized by the inflow of aseptic fluid present in the chamber (7). The container is then filled with a second injected aseptic fluid (9) supplied from a Primary supply line (39).

(8) FIG. 8 shows the Perforator means or device (105). A simplified production line direction (1). A filled container has a cap or seal (3) enclosing a headspace (5) defining a first fluid level (4) enters the Perforator means or device area (105). The cap has redundant material (3a) designed to control the flow direction of any melted material (16). A Laser emitter (14) emits a Laser cutting beam (14a) which quickly perforates the cap (8). Aseptic fluid of liquid or gas (7) is introduced

(9) FIG. 9 A production line direction (1). A cap (3) has a thin segment (60) designed in its center and this area is targeted by the puncture mechanism (6) to allow aseptic gas or fluid or liquid to flow through the opening (62).

(10) FIG. 10 A production line direction (1). A cap (3) has an upwardly protruding section (80). A cutting mechanism (81) that dislodges the protruding section (82).

(11) FIG. 11 shows the Sealing means or device (106). A production line direction (1). The container has a perforated cap (8) and Seal applicator means (28) applies a seal (21) resealing the container (44). Then the Seal applicator then disengages from the resealed container cap (17). The Secondary fluid supply line (40) may be configured to provide an aseptic pressurizing gas.

(12) FIG. 12 shows a production line direction (1), a perforated cap (8) with a raised portion of redundant cap material (3a) which the seal applicator (28) rearranges and thereby reseals (44) the container cap (17). A Secondary fluid supply line (40) that enters the Sealing means or device (106).

(13) FIG. 13 shows a production line direction (1), a perforated cap (8) with a raised portion of redundant cap material (3a) which the seal applicator (28) introduces new sealing material (21) and rearranges and thereby reseals (44) the container cap (17). A Secondary fluid supply line (40) that enters the Sealing means or device (106).

(14) FIG. 14 shows a Sealing means or device (106). A production line direction (1). A filled container has a perforated cap (8). After which a Laser emitter (14) fires a Laser beam (14a) toward the hole (62). This quickly melts the cap (16) resealing the hole in the cap (17).

(15) FIG. 15 shows a production line moving direction (1) beginning with a cooler (13) producing cooled, filled and capped containers (12). An accumulation device (29) passing containers onto the aseptic environment (111) of the Aseptic Line Converter Chamber (104) through the entry tunnel (108) the containers are passed to the Perforation means or device (105) containing a Perforation mechanism (6). The container is conveyed by means of rotary star-wheel conveyer (107) to the Sealing means or device (106), in which is located in a Rotary sealing system (27). The Secondary fluid supply line (40) enters the system. Then the Vacuum Modified Re-sealed container (18) leaves from the Exit port (109).

(16) FIG. 16 shows a production line moving direction (1) beginning with a cooler (13) with a water spray (13b) producing cooled, filled and capped containers (12). An accumulation device (29) passing containers onto the aseptic environment (111) of the Aseptic Line Converter Chamber (104) through the entry tunnel (108) the containers are passed to the Perforation means or device (105) containing a Perforation mechanism (6). The container is conveyed by means of rotary star-wheel conveyer (107) to the Sealing means or device (106), in which is located in a Rotary sealing system (27). Then the Vacuum Modified Re-sealed container (18) leaves from the Exit port (109).

(17) FIG. 17 shows a production line direction (1) where the Aseptic Line Converter Chamber (104) could be integrated into the production line. A Pre-form heating system (32) leads to a container blowing at station (33). The containers are then sent to the filler and capper (34). The containers are then conveyed to the inverter (102). Following this the containers are cooled in the cooler (13) before entering the Aseptic Line Converter Chamber (104). The container moves either to an accumulation table (290) or through the conveyor system (291). Following this a labeler (35) and packer (36).

REFERENCE NUMERALS

(18) (1) Direction of the production line. (2) Empty container. (3) Cap or seal. (3a) Raised cap portion. (4) Fluid level. (4a) Lowered Fluid level. (5) Headspace. (6) Perforator mechanism. (6b) Perforator injector barrel openings. (7) Ambient aseptic fluid flow direction. (8) Perforated cap. (9) Injected aseptic fluid flow direction. (11) Filled and capped or sealed container. (12) Filled, capped and cooled container. (13) Cooling Device. (13a) Cooler fluid dispenser. (13b) Cooling Fluid. (14) Laser emitter. (14a) Laser beam. (15) Cleaning step. (16) Melted cap material. (17) Resealed container cap. (18) Vacuum Modified Re-sealed container. (19) Labelled and processed container. (20) Container vacuum distortion. (21) Seal. (27) Rotary sealing system. (28) Seal applicator. (29) Accumulation device. (31) Beverage. (32) Pre-form heater. (33) Bottle blowing. (34) Filling and Capping. (35) Labeler. (36) Packer. (39) Primary fluid supply line. (40) Secondary fluid supply line. (44) Resealing container. (60) Thin section of cap. (62) Hole in cap. (80) Upwardly protruding section of cap. (81) Cutting mechanism. (82) Dislodged protruding section of cap. (102) Container inverter. (102a) Container reversion. (104) Aseptic Converter Chamber. (104b) Sterilization/Sanitization means. (104c) Sterilization/Sanitization device. (105) Perforator means or device. (106) Sealing means or device. (107) Conveying step. (108) Entry port. (109) Exit port. (110) Filtered gas Inflow. (111) Aseptic Environment. (112) Slight positive pressure. (113) Slight negative pressure. (290) Accumulation table. (291) Conveyor system.