DEVICE FOR FILLING CONTAINERS AND METHOD FOR MONITORING THE FILLING PROCESS

Abstract

Device for filling a container with a filling product, for example in a beverage filling system, and method for monitoring a filling process, wherein the device comprises: at least one filling member with a product chamber for receiving the filling product and introducing the filling product via an outlet into the container to be filled; and a measuring portion with a least one spectral sensor which is configured to determine one or more properties of the filling product on the basis of a spectroscopic measuring principle.

Claims

1. A device for filling a container with a filling product, comprising: a filling member comprising a product chamber that is configured to receive the filling product and to introduce the filling product via an outlet into the container; and a measuring portion comprising a spectral sensor that is configured to determine one or more properties of the filling product based on a spectroscopic measuring principle.

2. The device of claim 1, wherein the one or more properties of the filling product comprise a Brix content, a CO.sub.2 content, a density, a composition, and/or a mixing ratio of the filling product.

3. The device of claim 1, wherein the spectral sensor is installed in the product chamber, and the filling product comprises a filling product in the product chamber.

4. The device of claim 1, further comprising a discharge portion having a discharge that is connected to the product chamber and is configured to discharge liquid from the product chamber by bypassing the container, wherein the spectral sensor is installed in the discharge.

5. The device of claim 1, wherein the spectral sensor comprises a transmitter and a receiver, wherein the transmitter is configured to transmit a measuring beam emitted from the transmitter through at least a part of the filling product and the receiver is configured to receive the measuring beam from the transmitter.

6. The device of claim 5, wherein the measuring beam is reflected on a path from the transmitter to the receiver from at least one reflective surface.

7. The device of claim 1, further comprising a controller configured to control a filling process, wherein the controller is in communication with the spectral sensor and is further configured to measure a difference between a first base liquid and a second base liquid in or out of the filling member via the spectral sensor.

8. The device of claim 7, wherein the controller is further configured to measure an absorption in a viewing path through which the first base liquid and the second base liquid flow alternately via the spectral sensor.

9. The device of claim 1, wherein the filling member further comprises a main inlet that is configured to introduce the filling product or a main component of the filling product into the product chamber.

10. The device of claim 9, wherein the filling member further comprises one or more dosing valves, which are each configured to introduce an additional component into the product chamber.

11. The device of claim 9, further comprising a flow meter and a controller configured to control a filling process, wherein: the flow meter is installed in the main inlet, the controller is further configured to introduce the main component into the product chamber, and then to introduce an additional component into the product chamber via a dosing valve, and the controller is further configured to determine a quantity of fluid passing in the main inlet via the flow meter for dosing the additional component.

12. The device of claim 9, wherein the product chamber is of an annular configuration and tapers in a lower region to form an annular outlet so that the filling product is swirled when introduced into the container, and the main inlet leads tangentially into the product chamber.

13. The device of claim 12, wherein the filling member further comprises a valve cone having a cylindrical shape that tapers toward the annular outlet and is displaceable via an actuator in an axial direction, and the actuator is configured to adjust the valve cone between an open position and a closed position.

14. A method for monitoring a process for filling a container with a filling product, comprising: introducing a liquid into a product chamber of a filling member, wherein the filling member is configured to introduce the filling product into the container; and determining one or more properties of the liquid based on a spectroscopic measuring principle via a spectral sensor of a measuring portion.

15. The method of claim 14, wherein the one or more properties of the liquid comprises a Brix content, a CO.sub.2 content, a density, a composition, and/or a mixing ratio of the liquid.

16. The method of claim 14, further comprising measuring a difference between a first base liquid and a second base liquid in or out of the filling member via the spectral sensor.

17. The method of claim 16, wherein measuring the difference between the first base liquid and the second base liquid comprises measuring an absorption in a viewing path through which the first base liquid and the second base liquid flow alternately via the spectral sensor.

18. The method of claim 14, wherein the filling product comprises a main component and an additional component, and the method further comprises: introducing the main component from a main inlet of the filling member into the product chamber; introducing the additional component via a dosing valve into the product chamber; and determining a mixing ratio between the main component and the additional component via the spectral sensor.

19. The method of claim 18, wherein the main component comprises water and the additional component comprises a syrup and/or carbon dioxide.

20. The method of claim 14, further comprising: installing a flow meter in a main inlet of the filling member; introducing a main component into the product chamber; after introducing the main component, introducing an additional component via a dosing valve; and determining a quantity of fluid that passes in the main inlet via the flow meter for dosing of the additional component.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0041] Further embodiments of the invention are explained in more detail by the following description of FIG. 1, which shows schematically a device 1 for filling a container 100 with a filling product.

DETAILED DESCRIPTION

[0042] Exemplary embodiments are described hereinafter by way of FIG. 1, which shows schematically a device 1 for filling a container 100 with a filling product.

[0043] The device 1 is in some embodiments used in a beverage filling system, for example for filling water (still or carbonated), beer, juice, soft drinks, smoothies, dairy products and the like. The device 1 is in an exemplary embodiment implemented in a carousel design in which the containers 100 to be filled are supplied to a filler carousel and during transport are filled with the filling product along a pitch circle.

[0044] The device 1 is in one embodiment configured to fill the container 100 with a multi-component filling product. In this case, the filling product comprises at least two product components which are also denoted herein as the main component H and the additional component Z. The main component H is in certain embodiments water and the additional component Z can be, for example, syrup. In various embodiments, the filling product can be soft drinks. However, there is no restriction in this regard. For example, the main and additional component H, Z can be milk of variable fat content, in order to be able to set a desired fat content in a flexible manner in the filled product. Alternatively, it is possible to fill juices with pieces of fruit, wherein pulp is mixed as an additional component Z with a juice main component H. The additional component Z can comprise additives, flavourings, carbonated water, etc. Applications outside the beverage or food industry are also possible, for example in the care sector, for filling shampoo and the like.

[0045] In the exemplary embodiment of FIG. 1, the device 1 is configured to mix and to introduce into the container 100, in addition to the main component H, two additional components, namely a first additional component Z1 and a second additional component Z2.

[0046] The device 1 is suitable for a rapid, flexible product changeover, in particular when the various filling products are based on a common carrying mediumthe main component Hand various additivesthe additional components Z, Z1, Z2.

[0047] The device 1 has a filling member 10 which according to the exemplary embodiment of FIG. 1 is able to swirl the filling product when introduced into the container 100. To this end, the filling member 10 has a product chamber 11 which is configured as an annular channel or torus. The filling member 10 also has a main inlet 12 which in several embodiments leads tangentially or substantially tangentially into the product chamber 11. The main inlet 12 comprises a main valve 12a, a flow meter 12b and is connected to a filler vessel 2 which provides the main component H.

[0048] In the lower region of the filling member 10, the product chamber 11 tapers to form an annular outlet 13 from which the filling product exits during the filling process and runs into the container 100 placed below the filling member 10.

[0049] It should be mentioned that spatial references, such as for example under below, over, above, etc. refer to the usual installation position of the filling member 10 which is clearly determined by the direction of gravity. Moreover, due to the annular outlet 13 the filling member 10 has a defined axial direction which in the installed state at least substantially coincides with the direction of gravity.

[0050] The filling product is swirled by the annular product chamber 11 and the tapering outlet 13, assisted by the in one embodiment tangential supply of the filling product from the main inlet 12 into the product chamber 11, whereby this filling product is forced outwardly due to centrifugal force and after exiting from the filling member 10 flows downwardly on the container wall 101. The tapering or constriction of the product chamber 11 toward the outlet 13 leads, on the one hand, to a uniform and well-defined swirl across the periphery.

[0051] According to the exemplary embodiment of FIG. 1, the filling member 10 has a valve cone 14 which has a cylindrical shape tapering toward the outlet 13. The annular gap adjoining the product chamber 11 is formed on the inside at least in some portions by the outer peripheral surface of the valve cone 14. On the outside the annular gap is defined or formed by a valve housing 15. The valve cone 14 is configured to be displaceable in the axial direction, i.e. upwardly and downwardly. In this manner, the annular gap can be increased and reduced at the outlet 13. The height of the valve cone 14 is adjusted within the working range, i.e. in some embodiments steplessly between a fully open position and a closed position, actuated by means of a suitable actuator 16. If a valve seat is formed by the internal shape of the valve housing 15, the valve seat being sealingly in contact with the valve cone 14 in the closed position of the filling member 10, the outlet 13 can be fully closed, whereby a blocking function can be implemented.

[0052] Alternatively, a different suitable valve can be installed in order to open, close and optionally regulate the flow of filling product from the product chamber 11 into the container 100.

[0053] The lateral main inlet 12, i.e. leading tangentially into the product chamber 11, provides space above the product chamber 11. The space is not occupied and can be used for the assembly of a diaphragm 17 which seals the product chamber 11 in the upper region. The diaphragm 17 has a circular outer contour which is connected directly or indirectly to the valve housing 15. The diaphragm 17 is also fastened radially inwardly to the valve cone 14. The diaphragm 17 is produced from a flexible material, for example Teflon, whereby it can follow the axial movement of the valve cone 14 and at the same time ensures a hygienic seal of the product chamber 11. The symmetry of the diaphragm 17 also permits an embodiment with a high number of stress cycles as is generally required for filling valves.

[0054] The filling member 10 in some embodiments has a gas channel 18 which passes centrally through the valve cone 14 in the axial direction. The gas channel 18, for example, is a return gas channel in order to discharge any gas, such as pressurized gas, which is displaced from the container 100 during the filling process. The gas channel 18, however, can also have a multi-channel construction, for example a tube-in-tube construction, in order to provide separate supply and discharge gas paths.

[0055] The valve cone 14 terminates substantially directly below a throttle point, i.e. the narrowest point of the annular gap forming the outlet 13, whereby a defined change is implemented from a single-phase gap flow to a wall film flow in the container 100. Thus a well-defined uniform separation edge of the liquid is formed and namely at the point with the highest flow rate. In several embodiments, the valve seat, i.e. the blocking point, is located in the immediate vicinity of the separation edge, whereby the surfaces which could result in dripping are minimized.

[0056] The filling member 10 is particularly suitable for the wall filling set forth above, in which the filling product runs spirally downwardly on the container inner wall 101. However, the filling member 10 can also be constructed as a free flow valve. The filling member permits a full flushing of the valve interior, in particular the product chamber 11 and the outlet 13 which is adjacent thereto in the filling direction with a minimal flushing quantity, due to the high turbulence which can be achieved in the product chamber 11 and a relatively small surface area. For this reason, the filling member 10 is particularly suitable for a frequent changeover, for example including the containers, of the filling product, in particular additional components Z, Z1, Z2 to be dosed. Due to the excellent flushability, the filling member 10 can also be used in aseptic filling machines.

[0057] The compact design of the filling member 10 also permits a hygienic integration of the valve cone drive or actuator 16, and optionally further control functions in the valve head, i.e. above the product chamber 11, for example an integration of gas valves for pretensioning the container 100, return gas lines, pressure relief lines, solenoid valves for further separate control functions in the region of the filling member 10, such as lifting and lowering the valves, dosing components, etc. In addition, for example, a control board can be installed for implementing decentralized control architectures in the valve head.

[0058] In order to implement a rapid product changeover, substantially without changeover time, the filling member 10 has one or more, for example two, dosing valves 19a, 19b which are installed in corresponding supply lines for the additional components Z, Z1, Z2 leading into the product chamber 11. The additional components Z, Z1, Z2 can be dosed in the desired quantity into the product chamber 11 via the dosing valves 19a, 19b.

[0059] The mixing of the additional components Z, Z1, Z2 is carried out directly in the product chamber 11 by the dosing valves 19a, 19b, whereby a good flushability of the filling member 10 is ensured and any flavour carry-over is minimized. Due to the integration of the supply of additional components Z, Z1, Z2 in the valve housing 15, no hoses or additional lines are required. In this manner, the filling member 10 is suitable for an immediate product changeover.

[0060] The main inlet 12 comprising the flow meter 12b, in combination with the dosing valves 19a, 19b, permits dosing by rearward displacement. The filling product is directly mixed together from a plurality of componentsthe main component H and the additional components Z, Z1, Z2in the product chamber 11 of the filling member 10, wherein the additional components Z, Z1, Z2 are introduced via the dosing valves 19a, 19b into the product chamber 11. The main component H previously supplied through the main supply 12 is displaced to the rear by the introduction of the additional components Z, Z1, Z2 into the product chamber 11. The displaced volume of the main component H is determined by means of the flow meter 12b, and thus the volume of the dosed additional component(s) Z, Z1, Z2 is also known and controllable. When the filling product is subsequently filled into the container 100, the main component H together with the dosed additional components Z, Z1, Z2 are flushed completely out of the filling member 10 into the container 100, wherein at the same time the total filling quantity can be determined by the same flow meter 12b. In the next filling cycle, the filling quantities and also the quantities of the dosed component can be determined again. Thus a highly flexible filling of customized filling products, in particular beverages, is possible substantially without changeover times.

[0061] Optionally a discharge portion 20 is connected to the filling member 10, the liquid located in the product chamber 11 being discharged thereby, in particular returned to the filler vessel 2, and/or being able to be removed/disposed from the system. The discharge portion 20 comprises a discharge 21 and a discharge valve 22 which connects the discharge 21 to the product chamber 11 in a blockable manner.

[0062] The device 1 also has an integrated measuring portion 30 which is integrated, in particular, in the filling member 10 and/or in the discharge portion 20 and which is configured to detect on the basis of a spectroscopic measuring principle properties of the filling product, for example the Brix content, CO.sub.2 content, density, mixing ratio, etc. To this end, the measuring portion 30 has one or more spectral sensors 31, 32 which function individually or in cooperation with a corresponding electronic device or controller 50 as a spectrometer.

[0063] In some embodiments, the measuring portion 30 is configured to determine a mixing ratio between the main component H and the one or more additional components Z, Z1, Z2.

[0064] In various embodiments, the discharge portion 20 and the product chamber 11 of the filling member 10 are considered as installation locations for the spectral sensors 31, 32. In the exemplary embodiment of FIG. 1, both a spectral sensor 31 on the discharge side and a spectral sensor 32 on the product chamber side are installed. However, a single spectral sensor 31, 32 for each filling member 10 is sufficient for most applications.

[0065] The spectral sensor 31 on the discharge side can be installed in the discharge 21 between the filling member 10 and the filler vessel 2. The discharge valve 22, in several embodiments configured as a changeover valve, and possibly a pump (not shown in FIG. 1) are installed to this end. In one or more embodiments, a plurality of changeover valves are provided for each filling member 10. The spectral sensor 31 on the discharge side can either be installed in the discharge 21 directly downstream of the filling member 10 or in a central collection line which is connected to all, or at least a plurality of, filling members 10. It is advantageous if the discharge 21 is configured as a drainage line which does not lead back to the filler vessel 2, and the spectral sensor 31 on the discharge side is inserted in the drainage line. In this case, the hygiene requirements for the spectral sensor 31 on the discharge side are lower since the liquid removed via the drainage line is removed from the production process.

[0066] The spectral sensor 32 on the product chamber side can be installed as an alternative or additional spectral sensor directly in the product chamber 11 of the filling member 10.

[0067] The above-mentioned spectral sensors 31, 32 can have a transmitted light structure with a transmitter and receiver so that the measuring beam emitted by the transmitter passes through at least one part of the product to be measured and can be received from the transmitter and analysed spectroscopically. The measuring beam is in one embodiment light, wherein wavelengths outside the visible spectrum can be encompassed. Reflective solutions are also possible here, namely by using mirrors or a sensor system based on the reflection of stainless steel surfaces with an inlet and outlet point, by using sapphire windows, for example.

[0068] The signal path of the spectral sensor 32 on the product chamber side can be used during the dosing process for the monitoring thereof. An increase in the signal, when the filling member 10 has been flushed after a filling process, is an indication of a leakage.

[0069] Alternatively, it is also possible to implement a density measurement which, in particular, is relevant for sugar-containing filling products.

[0070] A controller 50 which is in communication with the actuator 16 of the valve cone 14, the valves 12a, 19a, 19b, 22, the sensors 31, 32, the flow meter 12, etc. is provided for activating the filling member 10, the discharge portion 20, the measuring portion 30, etc. and is configured to control or regulate the filling process and the product monitoring.

[0071] The communication between the controller 50 and the components to be activated and/or read can be implemented in a wired or wireless, digital or analogue manner. The communication does not necessarily have to comprise an information exchange in both directions. A unidirectional data and/or signal flow falls under the term communication. The controller 50 does not necessarily have to be formed by a central computing device or electronic control system, but it comprises decentralized and/or multi-stage systems, control networks, cloud systems and the like. The controller 50 can also be an integral component of a higher-level system controller or communicate therewith.

[0072] According to an exemplary embodiment, which targets the monitoring of an undesired leakage in the filling member 10, the controller 50 is configured to carry out a measurement of the difference between a pure or clean base liquid and the base liquid in or out of the filling member 10, in particular the product chamber 11. The base liquid can be the filling product itself or a component thereof, in particular the main component H. In one or more embodiments, the base liquid is water. The clean or pure base liquid, which in various embodiments does not pass through the filling member 10, functions here as a reference liquid. In this manner, for example, it is possible to determine any leakage in the filling member 10 and the tendency of the filling member 10 to flavour carry-over.

[0073] The difference measurement can be carried out, for example, daily or with each flushing process for cleaning/preparing the filling member 10. The absorption is measured in one or more suitable wavelengths in a viewing path through which both liquids flow alternately. Even minimal carry-over can be verified from the difference, including the ppm or ppb range.

[0074] The spectral measurement by means of an integrated sensor system, set forth above, permits the inline verification of deviations in dosages, even for small concentrations, and the detection of the smallest quantities of flavourings from previous products. Without the verification thereof, the flavourings carried-over from an earlier filling process would be flushed out later from the filling member 10 and thus could inadvertently pass into a different product and impair the quality thereof.

[0075] The measuring principle permits an inline monitoring at the latest possible measuring time, namely directly in the filling member 10 or in the discharge portion 20, and thus guarantees the desired product quality which is ultimately to be found in the container 100. Incorrect dosages, flavour carry-over and potential leakages can be identified and the containers 100 affected thereby can be ejected accordingly. A hundred-percent quality control of each individual container 100 is possible in this manner.

[0076] Since the measuring portion 30 is integrated in the device 1, the quality control is carried out irrespective of the type of container. It is equally applicable to PET and glass bottles, cans, paper containers and other types of container. This represents a significant simplification in comparison with random container testing, for example.

[0077] In principle, the measuring portion 30 can also be used for the process control, but in some embodiments is not incorporated in the process control, whereby the measuring portion 30 is solely responsible for the quality control.

[0078] If applicable, all of the features which are shown in the exemplary embodiments can be combined together and/or exchanged for one another without departing from the scope of the invention.