Method and device for cleaning and/or disinfecting a device for producing containers filled with a liquid filling material

A device for the integrated production and filling of containers and a method for cleaning and/or disinfecting at least the mold of at least one molding and filling station of the device. During a cleaning and/or disinfecting operation of the device, at least the inside of the mold is cleaned and/or disinfected with at least one cleaning and/or disinfecting agent by at least one cleaning element. During the cleaning and/or disinfecting operation, the at least one mold is opened and closed at least once, preferably many times and/or the plunger is moved at least once, preferably many times, between its initial position and end position.

The present application is a 371 of International application PCT/EP2012/001644, filed Apr. 17, 2012, which claims priority of DE 10 2011 102 090.3, filed May 19, 2011, the priority of these applications is hereby claimed and these applications are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention relates to a method for cleaning and/or disinfecting a device for producing containers filled with a liquid filling material.

Known is the production of containers by blow molding from preforms made of a thermoplastic material, for example from preforms made of PET (polyethylene terephthalate), wherein the preforms are supplied to different treatment stations within a blowing machine (DE-OS 43 40 291). Typically, a blowing machine has a heating apparatus for tempering or preheating (thermally conditioning) the preforms and a blowing device with at least one blowing station in whose area the respective, previously tempered preform is expanded biaxially or multiaxially to form a container. The expansion is effected using a pressurised gas (compressed air) as a pressure medium which is introduced, at a molding pressure, into the preform to be expanded. The process technology for such an expansion of the preform is explained in DE-OS 43 40 291.

The basic design of the blowing station is described in DE-OS 42 12 583. Options for tempering the preforms are explained in DE-OS 23 52 926.

According to a typical further processing operation, the containers produced by blow molding are supplied to a subsequent filling device where they are filled with the intended product or filling material. Thus, a separate blowing machine and a separate filling machine are used. In this context, it is also known to consolidate the separate blowing machine and the separate filling machine to form a machine block, i.e. to form a blocked blowing-filling device wherein, furthermore, the blow molding and the filling are performed on separate machine components, and sequentially.

Furthermore, it has already been proposed to produce containers, especially in the form of bottles, from thermally conditioned or preheated preforms and to simultaneously fill them with a liquid filling material which is supplied as a hydraulic pressure medium for expanding the preforms or for shaping the container at a molding and filling pressure so that, simultaneously with the filling, the respective preform is formed to produce the container. A particular problem of such a method is that it is essential to avoid contamination of the respective molding and filling station or of the mold that constitutes this station, said mold, similar to a blow mold of a blow molding machine for producing containers, being made from thermally conditioned performs by blowing with a pressurised gas. Especially in case of full or partial carbonisation of the filling material, there is the particular risk of contaminating the respective molding and filling station by filling material losses, especially when lowering the internal pressure of the container, i.e. when relieving the container of the rather high molding and filling pressure down to ambient pressure. Such filling material losses are especially due to massive foaming during relief, so that the simultaneous molding and filling of containers using preforms and using the filling material as a pressure medium (hydraulic shaping technology), especially for products containing CO2, could previously not be used.

At the end of the respective molding and filling process, filling material inevitably remains at or in the molding and filling elements. This filling material, for example, drips off at least partially and/or distributes due to the air movement in the inside of the molds of the molding and filling stations, or, in case of machine faults or breakdowns possibly even in greater quantities, is flung into the inside of the molds of the molding and filling elements or into the molding and filling area of the device and thus also contaminates, in particular, critical surfaces, i.e. those surfaces which, during molding and filling, come into contact with the filling material and/or with surfaces of the containers that are close to the filling material and/or touch the filling material so that, by microbial contamination of the surfaces contaminated with the filling material, a microbiological risk occurs to the filling material but also to persons, especially the operating staff.

SUMMARY OF THE INVENTION

The task of the invention is to show a method which precludes a microbiological risk to the filling material and to humans during molding and simultaneous filling of containers.

For example, by regular cleaning and sterilisation or disinfection of the respective molding and filling station, a microbiological risk is precluded or at least minimised, e.g. in that the cleaning removes filling material residues to which microbial contamination could occur and, moreover, all areas, which are close to filling material, of the respective molding and filling station are sterilised or disinfected.

“Product-carrying areas” within the meaning of the present invention are those areas, especially ducts, lines etc. which, during the normal molding and filling operation, carry the filling material to be introduced into the preforms or into the containers being molded.

“Areas close to filling material” within the meaning of the invention are those areas or surfaces of the molding and filling station which come into direct contact with the filling material, especially the areas carrying filling material but also areas or surfaces which come into contact with surfaces, especially with the opening edge and the inner surface of the preforms and of the containers being molded and/or, during the molding and filling process, reach into the preform or into the containers being molded.

“Filling material inflow” within the meaning of the invention means the inflow which, for example, is formed by at least one delivery opening via which the liquid filling material, during the molding and filling process, is introduced into the respective preform or into the container being molded.

The expression “essentially” or “about” means, within the meaning of the invention, deviations from the respective exact value by +/−10%, preferably by +/−5% and/or deviations in the form of changes insignificant to the function.

Further developments, advantages and possible applications of the invention can also be taken from the following description of exemplary embodiments and from the figures. All features described and/or illustrated form the subject-matter of the invention per se or in any combination, independent of their inclusion in the claims or their back-reference. The content of the claims is also made part of the description.

The invention is explained in detail below with reference to the figures using exemplary embodiments, with:

DETAILED DESCRIPTION OF THE INVENTION

The device, generally designated1inFIGS. 1-6, serves to produce filled containers2in the form of bottles (FIG. 4) using preforms3made of a thermoplastic material, for example of polyethylene terephthalate (PET), polyethylene (PEE), polyethylene naphthalate (PEN) or polypropylene (PP). The preforms3, in the known manner, are of a sleeve-like design with an open end forming the subsequent container mouth and with a closed bottom forming the subsequent container bottom and with a flange forming the subsequent mouth flange (seeFIG. 5).

The containers2filled with a liquid filling material are always produced such that each conditioned perform3, which is at least preheated and arranged in a closed mold5of a molding and filling station4, is charged with the filling material which is at a high molding and filling pressure and, for example, heated for a hot sterile filling, so that the preform3, in a molding and filling process, is hydraulically shaped by this filling material into the respective container2and the container2is filled at the same time. The container2thus molded and simultaneously filled is then suitably closed after being relieved of the molding and filling pressure and following removal from the mold5.

To perform the molding and filling process, the device1has, at a rotatably drivable transport element in the form of a rotor6rotatably drivable about a vertical machine axis MA, a plurality of molding and filling stations4which are provided at an equal radial distance from the machine axis MA and, at equal angle distances, offset about this axis. Each molding and filling station4comprises, in addition to its mold5, a molding and filling element7which is arranged, in the embodiment shown, over this mold, said molding and filling element, at least during the respective molding and filling process, reaching into the closed mold5with a filling element portion or bearing head8and against which the respective preform3and the container2being molded rest, through support means (not shown) with an open end, pressed into the sealing position. In the embodiment shown, the rotor6is designed with a circular cylinder-shaped rotor portion6.1concentrically enclosing the machine axis MA and with an upper or lower annular rotor portion6.2or6.3distanced, like a flange, from the rotor portion6.1.

In the bearing head8, in the vertical direction, i.e. in the direction of a molding and filling element axis FA, an axially displaceable plunger9is provided which, with its lower rounded end inFIG. 5, during the molding and filling process, is initially moved downwards, in a controlled manner, resting against the bottom of the preform3concerned and then against the bottom of the container2being formed and thus controlling the shaping or stretching of the preform3into the respective container2in the axis FA. In the embodiment shown, the liquid filling material is also introduced into the preform3or into the container2being progressively molded via a fluid duct10which is formed in the plunger9and enters at openings11into the area of the lower end of the plunger9.

At the rotor6, a ring bowl12is provided which, during the molding and filling operation of the device1, is at least partly filled with the filling material subjected to molding and filling pressure and connected, via lines13having control valves13.1, with the filling elements7. Underneath the molding and filling stations4, a ring bowl14is provided at the rotor6, said ring bowl serving, for example in the manner described more detailedly below, as a collection bowl or collection container for collecting liquid cleaning and disinfecting agents during a cleaning and disinfection operation of the device1.

The preforms3are supplied to the individual molding and filling stations4or the opened molds5, in the embodiment shown, via a transport star15. After molding and filling, the filled containers2are removed from the re-opened molds5via a transport star16.

During the respective molding and filling process, filling material inevitably remains in the molding and filling elements7and especially in or at their bearing heads8and plungers9and then drips off, e.g. after removing each filled container2so that, due to air movements, internal and/or external contamination of the molds5with filling material occurs, especially when, due to machine faults, for example due to damaged or burst containers2, larger quantities of filling material enter the inside of the mold5.

To preclude the microbiological risk, emanating from germs forming on filling material residues, to the filling material filled into in the containers2and/or also to humans, for example the operating staff of the device1, regular cleaning and disinfection of all areas and/or functional elements of the device1, which come into contact with the filling material and/or with areas of the containers2which are close to the filling material, are required. This regular cleaning and disinfection is always performed in a multistage cleaning and disinfection operation.

During such a cleaning and disinfection operation, with the rotor6rotating, external cleaning and then internal cleaning of the molding and filling stations4are for example performed, always with at least one suitable liquid and/or foaming cleaning medium, e.g. via external nozzles not shown which, for example, are rotating and/or fixed nozzles and are provided at a machine frame which does not rotate with the rotor6and/or at the rotor6. During external cleaning, the cleaning agent is primarily applied to the external surface of the molds5, but also to inner surfaces of the molds5and to opening edges of the multipart molds5which, for this, are opened and closed in a controlled manner, as shown inFIGS. 1 and 2, so that all surfaces of the molds5are reliably treated with the respective cleaning medium. During internal cleaning, the molds5are closed, as shown inFIG. 3. For example, the cleaning medium is applied by inner nozzles and/or by the plungers9which, with the rotary motion of the rotor6, are moved up and down in a controlled manner.

At least from the closed molds5, the cleaning medium is drained via the lines15into the ring bowl14serving as a collection container or catch tank. Basic suitable cleaning media are liquid media, especially foaming media wherein, during the cleaning cycle, different cleaning agents can also be used sequentially.

After the cleaning cycle, external disinfection takes place and then internal disinfection of the molding and filling stations4with at least one suitable disinfecting agent which, during external disinfection, is applied in turn via outer rotating and/or fixed nozzles onto the external and internal surfaces of the molding and filling stations or the periodically opened and closed molds5and onto the edges of the molds5, said edges being exposed when the molds5are open, and during internal sterilisation of the closed molds5via internal nozzles and/or via the plungers9which, with the rotor6rotating, are in turn moved up and down in a controlled manner. In turn, the disinfecting agent is drained from the molds5via the lines15into the ring bowl14.

For example, a suitable liquid medium is used as a disinfecting agent. In principle, there is also the possibility that, during the disinfection cycle, several different media are used sequentially.

During the cleaning cycle and/or during the disinfection cycle, for example simultaneously, the cleaning and disinfection of such ducts, lines and/or functional elements also takes place which, during the normal molding and filling operation, come into contact with the filling material. In principle, there is the possibility of cleaning and sterilising these ducts, lines and functional elements in a ClP method, using rinsing caps18which, during this CIP cleaning and sterilisation, for example instead of the preforms3, are then supplied via the transport star16to the individual molding and filling stations which correspond to the shape of the preforms3and, during CIP cleaning and CIP disinfection, are arranged with their open end in the sealing position against the respective bearing head8, so that the utilised cleaning medium or disinfection medium for example after flowing through the ducts and lines etc. to be cleaned or disinfected, enters via the respective plunger9into the closed inside of the rinsing cap18and is drained via a return gas duct19formed in each bearing head8. If, during this CIP cleaning and CIP disinfection, the plungers9are in their raised state and, with the rotor6rotating, perform no axial movement, the rinsing caps18, which enclose or receive the respective plunger9, also correspond in terms of their size to the preforms3, so that, instead of the rinsing caps18e.g. made of a metallic material and/or of plastic, preforms3could be used which are not conditioned or not preheated.

If the plungers9perform, during CIP cleaning and CIP disinfection, with the rotor6rotating, their axial movement, the rinsing caps18have a greater axial length which enables the maximum stroke of the respective plunger9from its raised starting position to its lowest position.

Above, it was assumed that the molds5are self-emptying via the lines15connected to the ring bowl14, i.e. the respective cleaning agent and/or disinfecting agent drains, due to gravity, via the lines into the ring bowl14. However, in principle, there is also the possibility of actively emptying the molds5, for example by applying a negative pressure or suction effect, via the ring bowl14, to the lines15, for example by a pump connected to an outlet of the ring bowl14.

The molds5, for example, are provided with relief openings which, in the closed condition of the molds5and especially during the molding and filling process, are used as pressure relief and/or as drainage openings and/or as control openings and to which, for example, the lines15are connected.

Above, it was assumed that rinsing caps18are used for ClP cleaning and CIP disinfection. However, in principle, there is also the possibility that the respective tightly sealed mold5takes over the function of a rinsing cap, i.e. the inside of each mold5is part of the closed CIP cleaning circuit and/or of the closed CIP disinfections circuit. In this design, in particular, the relief openings at the molds5are of a closable design.

Above, it was assumed that the cleaning agent or disinfecting agent flows through lines and ducts which carry the filling material during the molding and filling operation in the course of ClP cleaning and/or CIP disinfection, in the filling material direction, i.e. in a flow direction in which the filling material also flows through these lines and ducts during the molding and filling operation. A flow through these lines and ducts against the filling material direction during ClP cleaning and/or CIP disinfection is also possible.

Preferably, during the molding and filling operation, individual molding and filling stations4are removed in case of missing and/or faulty and/or damaged preforms3and/or containers2and/or in case of errors in the molding and filling process. For example, this removal is controlled by suitable sensors in and/or at the molding and filling station or in and/or at the molds5and/or the molding and filling elements7and/or at the path of motion of the filled containers2, for example at the transport star17, and/or through signal exchange with other functional units of the system comprising the device1etc. In particular, it is thus possible to perform the cleaning and disinfection operation periodically, e.g. by way of time control and/or performance control, i.e. always depending on a certain number of formed and filled containers2without microbiological hazard risk.

As an alternative to the rinsing caps18, caps or rinsing bodies approximated to the shape of the containers2can also be used, said caps or rinsing bodies having, externally, a plurality of nozzle openings through which the cleaning agent and/or disinfecting agent is applied during internal cleaning and/or internal disinfection, for example, during CIP cleaning and/or disinfection, also onto the inner surfaces of the respective mold5.

Preferably after completion of cleaning and/or disinfection, preferably at the end of the cleaning and disinfection operation, at least the inner surfaces of the respective mold5are blown out with a sterile gaseous and/or vaporous medium, for example with sterile air.

FIGS. 7-9show, as a further embodiment, a device1awhich essentially differs from the device1only in that, for external and internal cleaning and for external and internal disinfection of the molds5, a cleaning and/or disinfection hood20is provided which, interacting with the rotor6or with the rotor portions1.6-6.3, forms an internal space which receives the respective mold5during cleaning and/or disinfection and which is outwardly closed or essentially closed.

The hood20, in respect of the machine axis MA, is intended to be radially movable or adjustable, namely from the initial position shown inFIG. 7to the working position shown inFIGS. 8 and 9, in which the hood20forms the closed space. At the inner surface of the hood20, a plurality of nozzles21are provided for applying the cleaning agent and/or the disinfecting agent. During the cleaning cycle and/or disinfection cycle, the rotor6is always cycled further by the mutual spacing of two molding and filling stations4, wherein, in each standstill phase of this cycled motion, the hood20moves from the initial position to the working position, then the external and internal cleaning and/or disinfection of the mold5concerned are performed and the hood20is then moved back to its initial position. During this cleaning and/or disinfection, the mold5received in the hood20is preferably opened and closed once or many times, in a controlled manner. Otherwise, the device1acorresponds, especially as regards the further process steps of the cleaning and disinfection operation, to the device1.

The invention was described above using exemplary embodiments. It is understood that numerous changes and modifications are possible without departing from the inventive idea underlying the invention.

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