Modulated pressure control of beverage fill flow

Abstract

A method and apparatus of filing beverage combines pressurized beverage delivery (rather than gravity feed) with variable pressure control of the beverage flow into the can. By modulating beverage flow and especially beverage pressure, it is possible to fill a can's widget (gas reservoir) with gas with a shorter set of fill steps. In addition, the speed of beverage filling can be dramatically increased compared to small scale systems normally used. Unlike known large scale pressure systems, the beverage bowl may be located beneath the rest of the apparatus and modulated pressure may be used, making for a smaller and more portable unit.

Claims

1. A beverage filling machine for use with a beverage can having an open top and a widget, the beverage filling machine comprising: a first fill station, the first fill station dimensioned and configured to hold such beverage can in place for filling; a fill head dimensioned and configured to be lowered to sit atop such beverage can, the fill head in liquid and gas communication with such beverage can; a beverage supply bowl located below the fill head; a pressurized gas source; a first beverage conduit connecting the beverage supply bowl to the fill head; a second gas conduit connecting the gas source to the fill head; a third gas conduit connecting the fill head to the beverage supply bowl head space; a fourth snift line connecting the fill head to a purge; a first variable progressive valve on the snift line; a second variable progressive valve on the second gas conduit; a third variable progressive valve on the third gas conduit; the variable progressive valves being controlled by variable air pressure; whereby such can may be filled from the beverage supply bowl by means of variable controlled pressure controlled by the variable progressive valves, and further whereby such widget may be filled with gas from the gas source by means of variable controlled gas pressure controlled by the variable progressive valves, a seamer disposed adjacent the first fill station, the seamer operative to affix a top to such can.

2. The beverage filling machine of claim 1, wherein the gas is one member selected from the group consisting of: CO2, N2, other inert gases, other food-grade gases, and combinations thereof.

3. The beverage filling machine of claim 1 for use with a second can having therein a second widget, the beverage filling machine further comprising: a second fill station, the second fill station dimensioned and configured to hold such second beverage can in place for filling; a second fill head dimensioned and configured to sit atop such second beverage can, the second fill head in liquid and gas communication with such second beverage can; a fifth beverage conduit connecting the beverage supply bowl to the second fill head; a sixth gas conduit connecting the gas source to the second fill head; a seventh gas conduit connecting the second fill head to the beverage supply bowl; an eighth snift line connecting the second fill head to the purge; a fourth variable progressive valve on the eighth snift line; a fifth variable progressive valve on the third gas conduit; whereby such second can may be filled from the beverage supply bowl by means of variable controlled pressure controlled by the variable progressive valves, simultaneously with the filling of such first can; and further whereby such second widget may be filled with gas from the gas source by means of variable controlled gas pressure controlled by the variable progressive valves, simultaneously with the filling of such first can's widget.

4. The beverage filing machine of claim 1, further comprising: a means for positioning such can in the first fill station and repositioning such can in such seamer.

5. The beverage filling machine of claim 4, further comprising a programmable logic controller operative to control the first through fifth valves by controlling the variable air pressure lines, and further operative to control the pressurized gas source, the lowering of the fill head and the means for positioning the can.

6. A method of filling a beverage can having an open top and a widget, the method comprising the steps of: providing a beverage filling machine comprising: a first fill station, the first fill station dimensioned and configured to hold such beverage can in place for filling; a fill head dimensioned and configured to sit atop such beverage can, the fill head in liquid and gas communication with such beverage can; a beverage supply bowl located below the fill head; a pressurized gas source; a first beverage conduit connecting the beverage supply bowl to the fill head; a second gas conduit connecting the gas source to the fill head; a third gas conduit connecting the fill head to the beverage supply bowl; a fourth snift line connecting the fill head to a purge; a first variable progressive valve on the snift line; a second variable progressive valve on the second gas conduit; and a third variable progressive valve on the third gas conduit; a seamer adjacent the first fill station; positioning such can in the first fill station; sealing the fill head to the top of such beverage can; in a first pressurization and first purge step, opening the first and second variable progressive valves so that gas flows from the pressurized gas source via the second gas conduit to the fill head and then into such can while allowing air within such can to leave the can via the fourth snift line, thereby pressurizing the can and the widget with gas; in a second pressurization and purge step, closing the first and second variable progressive valves and opening the third variable progressive valve so that such can becomes pressurized from the beverage supply bowl rather than the gas source and allowing pressure in such can to equalize to pressure in the beverage supply bowl and creating counterpressure for later steps of the filing; maintaining the counter pressure while supplying liquid from the beverage supply bowl to such can via the first beverage conduit; allowing the liquid to settle in such can whereby gas remaining in such can gathers at the top of such can; snifting the can by closing the third progressive variable valve and closing the first beverage conduit, but partially opening the first variable progressive valve on the fourth snift line, the partial opening sufficient to allow such can to depressurize down to an ambient air pressure by purging via the fourth snift line but insufficient to cause such widget to depressurize; moving such can to a seamer; seaming a top onto such can.

7. The method of filling a beverage can of claim 6, further comprising: providing variable air pressure lines; controlling the variable progressive valves by means of variable air pressure lines.

8. The method of filing a beverage can of claim 7, further comprising: providing a means for positioning such can in the first fill station and repositioning such can in such seamer.

9. The method of filling a beverage can of claim 8, further comprising: providing a programmable logic controller operative to control the first through fifth valves by controlling the variable air pressure lines, and operative to control the pressurized gas source, the lowering of the fill head and the means for positioning the can.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.

(2) FIG. 1 is a cross-sectional side view of a topless can with a widget.

(3) FIG. 2 is cross-sectional side view of a can under a fill head according to a preferred embodiment and best mode now contemplated for carrying out the invention.

(4) FIG. 3 is a cross-sectional side view of the same can during initial purge and pressurize.

(5) FIG. 4 is a cross-sectional side view of the same can during a second purge and pressurize for counter pressure.

(6) FIG. 5 is a cross-sectional side view of the same can as it is filling with beverage or other liquid.

(7) FIG. 6 is a cross-sectional side view of the same can during the “snift” as it is depressurized to atmospheric pressure.

(8) FIG. 7 is a schematic side view of a beverage filling machine according to the invention.

(9) FIG. 8 is a side view of a beverage filling machine according to the invention.

(10) FIG. 9 is a flow chart of the steps of the process of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

Glossary

(11) The term beverage or pressurized beverage or carbonated beverage as used herein includes but is not limited to beers, soda pop, soda water, sparkling wines, energy drinks, juices and mixtures thereof.

End Glossary

(12) FIG. 1 is a cross-sectional side view of a topless can with a widget. Beverage can, open top 100 has a normal proportion for a can which has not yet been “seamed”, that is, has no top during the filling process.

(13) Widget 102 sits atop the dome (the bottom of the can interior) with two openings from the widget interior to the can interior. Lower opening 104 and upper opening 106 allow the easy purging of oxygen from the widget and refilling the widget with N2 or CO2. So long as pressure is kept equalized, the small size of the openings (for example. 0.5 mm) means that the gas within the widget does not leave. When the can is opened, the immediate pressure drop causes outgassing from the widget into the beverage.

(14) FIG. 2 is cross-sectional side view of a can under a fill head according to a preferred embodiment and best mode now contemplated for carrying out the invention. Can 200 has fill head assembly 210 seated atop the open end, sealing it so pressure may be applied. This is in contrast to prior art craft brewery apparatus which have open gravity feed arrangements.

(15) FIG. 3 is a cross-sectional side view of the same can during initial purge and pressurize. Pressure is applied for the first time as CO2 inlet/outlet line 212 is being used to provide CO2 under pressure while the outlet line/snift line 214 is venting oxygen to a purge or to the atmosphere. (Oxygen is not allowable in a sealed beverage can.)

(16) FIG. 4 is a cross-sectional side view of the same can during a second purge and pressurize for counter pressure. CO2 is now being vented via the outlet line 214.

(17) FIG. 5 is a cross-sectional side view of the same can as it is filling with beverage: soda, sparkling wine, pop, or other liquid. Beverage 215 is flowing in by way of liquid inlet line 216, then flowing down the interior sides of the can (due to the configuration of the vents in the fill head), leaving a smaller and smaller pocket of CO2. Note that the CO2 is now being removed by the inlet/outlet line 212, and that CO2 may flow to the beverage bowl.

(18) FIG. 6 is a cross-sectional side view of the same can during the “snift” as it is depressurized to atmospheric pressure. CO2 at the top of the can interior is vented slowly until the pressure is reduced to the desired level, for example, atmospheric pressure.

(19) It may be seen that the cycle used in this filling is different from prior art cycles, as the use of pinch valves allows different flows. In particular, gas pressure can be modulated by the pinch valves used in the equipment so that during fill, and during purges, and also during the pressure relief post-fill, the pressure may be reduced slowly. This is advantageous in any beverage can or other carbonated or pressurized beverage context, but it is especially useful in the context of a widget, as the widget may be charged without inverting the can.

(20) In addition, it will be appreciated that the true double purge using CO2 offered by this system (in contrast to the prior art small scale equipment which does only a single, non-pressurized purge) allows a purge from the CO2 source but also a purge from the top of the beverage bowl, that is from the CO2 present in the beverage supply tank above the beverage. In addition, there is no need for pre-measurement and the bowl of the invention can be placed beneath the fill head, lowering the center of gravity, saving space, and making the unit more portable.

(21) FIG. 7 is a schematic side view of a beverage filling machine 320 according to the invention. The machine has more than one beverage filling station 322, the first having fill head assembly 310 as previously shown, which has a number of lines in and out of it: CO2 inlet/outlet line 312, outlet line/snift line 314, liquid inlet line 316, fill head to bowl CO2 line 332, and for the second beverage filling station 352 there is a second fill head assembly 340 having additional CO2 inlet outlet line 342, outlet line/snift line 344, liquid inlet line 346, head to bowl CO2 line 362 etc.

(22) Both beverage filling stations 322 and 352 are supplied by beverage supply bowl 324, which is partially filled with beverage 326 above which is CO2 328. This CO2 328 above the beverage in bowl is used as an additional source of CO2, a purge from the fill head/can and more, for example, this CO2 may be used for the second purge, while the gas source 330 is used for the first purge.

(23) Importantly, the invention uses variable progressive valves 334, 336, 364 and 366 to control beverage flow and CO2 pressure. These, as discussed, may allow gradual pressure application and withdrawal for faster and more effective filling of the cans. These may be, as shown in the diagrams, actuator/solenoid controlled pinch valves or the like, which testing has shown are vastly superior to known valves used in the industry in either large scale or small scale bottling. In addition, testing has shown that having one or more variable valves per can filling station is advantageous, as one valve controlling all five cans may not be as accurate in use.

(24) FIG. 8 is an end view, partially cross-sectional of a single filling station of a beverage filling machine 420 according to the invention. It will be understood that in preferred embodiments there are five stations, however, from an end view and for clarity only a single station 422 is shown. In practice, this means that instead of the two variable progressive valves (pinch valves) shown, there are actually ten valves, two per station, and a plurality of conduits, lines, etc.

(25) Pressure transducer 401 is used to measure pressure inside of the can and system during pressurization and other steps.

(26) Worm drive screw 403 is seen in an end on view. The threading of the screw is large enough that a line of cans fits into it, one can in each thread, and the cans are moved (directly out of the plane of the drawing toward the viewer) as the screw 403 rotates. By this mean the screw 403 indexes each can into position at station 422 or another station, as well as moving the cans further forward to the seamer after filling is complete.

(27) Purge manifold 405 (also called the clean-in-place re-circulation) captures chemicals and volatiles from the CO2 gas leaving the system before the CO2 is purged into the ambient atmosphere.

(28) On/Off valve 407 is controlled by air pressure fed to coupling 409: for clarity this coupling is shown but the additional line is omitted from this drawing. Note that the valve 407 does not actually control the flow of beverage into the can, though it does prevent it or allow it. In use, this valve is only opened after the counterpressure has been applied to the can, that is, this valve is shut while the pressure in the can is matched to the pressure in the beverage supply bowl. When they are connected and pressure is equalized, the valve 407 is opened. Since the pressure has been equalized however, no beverage flows through the open conduit 416 just yet. Rather, the gentle opening of variable progressive valve 434 allows the pressure in the can to drop by a very delicate and deliberate increment and beverage begins to flow per FIG. 5.

(29) Fill head assembly 410 is as described in FIGS. 2 through 6. It may be seen that the float ball valve is used to help regulate beverage fill and to prevent overfill.

(30) CO2 inlet/outlet line 412 comes from the gas source 430.

(31) Outlet line/snift line 414 has thereon variable valve 436 which also allows the final snift step (reducing pressure to atmospheric pressure after filling is complete) to be carried out in a controlled manner, with the objective of keeping the widget pressurized by avoiding sudden pressure changes which would allow gas in the widget to escape.

(32) Liquid inlet line 416 runs from the beverage supply bowl 424 to the fill head 410. Notice that variable valve 436 may be used to carry out the beverage filling operation without undue sudden pressure variations which would discharge the widget. After the can and widget have been pressurized, on/off valve 407 is opened while pinch valve 434 is allowed to gently release pressure from the can and fill head. Pressure in the beverage supply bowl 424 drives beverage or other product up line 416 and into the can as shown previously in FIG. 5, but without any pressure spikes or dips which would cause the CO2 or N2 previously charged into the widget (see FIGS. 3 and 4) to become discharged.

(33) Beverage supply bowl 424 has above the actual beverage, in the head space 424 of the bowl, pressurized CO2. This pressurized CO2 is not only used to drive beverage up line 416, it is also used for the counterpressure step (see FIG. 4), when the gas line (not visible in this view, see 332 and 362 of FIG. 7 for an example) from the top of the bowl to the fill head is opened.

(34) The head to bowl CO2 line (not visible in this view) allows equalization of pressure between the can and the beverage supply bowl: when the valve controlling this conduit is open, pressure may equalize and gas may in fact flow in either direction: from the bowl to the can or vice-versa.

(35) Variable progressive valve 434 and variable progressive valve 436, along with the counterpressurization of the can to equal the beverage supply bowl are thus all crucial to maintaining the widget in a charged state, since each of these parts and steps is necessary to keep the gas (inside of the ½ mm holes of the widget) from expanding out of the hole(s). For example, if valve 434 was a simple on/off valve such as valve 407, when it was opened to begin allowing beverage in, the sudden pressure change in the system and in the can would get the gas in the widget flowing out the holes. Similarly, if the snift valve 436 was a simple on/off, when the can pressure was reduced to ambient there would be a sudden plunge in pressure and the widget would outgas.

(36) Outlet line/snift line 414, unlike the head to bowl line, purges completely from the can to ambient atmosphere or other gas disposal volumes. As discussed previously, by using valves allowing fine control, in particular with valves which can partially open such as progressive valves, it is possible to depressurize the can slowly enough that the equilibrium of the widget, which has very small holes therein (0.5 millimeter, as discussed previously) is not disturbed and the widget remains pressurized with gas at the pressure established during filling, the pressure of the beverage supply bowl or the gas supply, even though the can in which it sits slowly depressurizes to ambient pressure. This is due to the small size of the holes where the gas inside the widget is in contact with the beverage outside the widget inside the can. As noted previously, when a user opens the can the pressure drop is quite dramatic by comparison and that change instantly disturbs the equilibrium of the widget holes and the gas floods out through the holes into the beverage, instantly carbonating (or nitrogen over-saturating) the beverage or other liquid.

(37) FIG. 9 is a flow chart of the steps of the process of filing a can using the device of the invention. The method of filling is in fact key to the invention, in particular the use of multiple pressurize and purge cycles combined with variable progressive valves allowing a widget to be filled with gas while upright and quite quickly in comparison to the multiple cycle method of prior art discussed above (six seconds, four seconds, six seconds, four seconds, etc).

(38) In a preferred method and best embodiment of the invention, a can is indexed 502 below the fill head and the fill head sealed 504 to the can, then a variable pressure valve (as opposed to a binary on-off valve) is used to provide (506) CO2 or N2 from a CO2/N2 source through a first inlet line. At the same time, oxygen is allowed to leave 508 the can through a second outlet line. Then as CO2 is provided (506) to the can, the can is pressurized 510 from the CO2 in the beverage bowl, (by way of the same port in the fill head as the first inlet line, but using a third head-to-bowl gas line) thus equalizing pressure 512 to that of the beverage bowl pressure and allowing counter pressure for later steps. During this second purge CO2 is allowed to escape from the second outlet line. Next, liquid is supplied 514 (any pressurized or carbonated beverage) from the beverage bowl while CO2 is withdrawn 516 back into the beverage bowl from the can by way of the head to bowl gas line. A settle step 518 allows the beverage to settle in place from running down the walls of the can, and allows the CO2 or N2 gas to gather at the top before a “snift” step 520 in which the variable valves are yet again used to slowly bring the can down to ambient pressure by allowing CO2 to escape via the second outlet line, but keeping the widget pressurized 522. Finally, the can is moved 524 to a seamer and the top applied 526.

(39) Throughout this application, various publications, patents, and/or patent applications are referenced in order to more fully describe the state of the art to which this invention pertains. The disclosures of these publications, patents, and/or patent applications are herein incorporated by reference in their entireties, and for the subject matter for which they are specifically referenced in the same or a prior sentence, to the same extent as if each independent publication, patent, and/or patent application was specifically and individually indicated to be incorporated by reference.

(40) Methods and components are described herein. However, methods and components similar or equivalent to those described herein can be also used to obtain variations of the present invention. The materials, articles, components, methods, and examples are illustrative only and not intended to be limiting.

(41) Although only a few embodiments have been disclosed in detail above, other embodiments are possible and the inventors intend these to be encompassed within this specification. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way. This disclosure is intended to be exemplary, and the claims are intended to cover any modification or alternative which might be predictable to a person having ordinary skill in the art.

(42) Having illustrated and described the principles of the invention in exemplary embodiments, it should be apparent to those skilled in the art that the described examples are illustrative embodiments and can be modified in arrangement and detail without departing from such principles. Techniques from any of the examples can be incorporated into one or more of any of the other examples. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.