Patent Publication Number: US-6209591-B1

Title: Apparatus and method for providing container filling in an aseptic processing apparatus

Description:
This application claims benefit to U.S. provisional application Serial No. 60/118,404, filed Feb. 2, 1999. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to systems for the aseptic packaging of food products. More particularly, the present invention relates to an apparatus and method for providing container product filling in an aseptic processing apparatus. 
     BACKGROUND OF THE INVENTION 
     Sterilized packaging systems in which a sterile food product is placed and sealed in a container to preserve the product for later use are well known in the art. Methods of sterilizing incoming containers, filling the containers with pasteurized product, and sealing the containers in an aseptic sterilization tunnel are also known. 
     Liquid product fillers are known in the art. Generally, a container is placed under a filler head. The filler head opens and dispenses the liquid product. When the container is filled to a desired level, the filler head closes and stops the flow of liquid product into the container. Commonly, in line aseptic fillers use completely mechanical devices for measuring and dosing product into containers. These devices include a first apparatus for measuring the amount of material to be dispensed, and a second apparatus which functions as a filling nozzle. Typically, the first apparatus includes a piston cylinder apparatus for measuring the amount of material. The amount of material measured by the piston cylinder apparatus is limited by the diameter and stroke of the piston. The first and second apparatus include complicated mechanical members which are difficult to sterilize, clean, and maintain. 
     Typically, rotary fillers include multiple filling stations and allow about 7 to 15 seconds for filling. Some of the rotary bottle filers use electronic measuring devices for dosing the desired amount of product into a bottle. In order to meet FDA (Food and Drug Administration) “aseptic” standards and 3A Sanitary Standards, all surfaces of the filler that come into contact with the liquid product must be sterilized. Before filling commences, a plurality of interior parts of the filler must be removed, sterilized, and replaced. This time consuming and expensive process is necessary in order to ensure the complete sterilization of all surfaces that come into contact with the liquid product. 
     Packaged food products can generally be categorized as high acid products (Ph below 4.5) or low acid products (Ph of 4.5 and above). The high acid content of a high acid product helps to reduce bacteria growth in the product, thereby increasing the shelf life of the product. The low acid content of a low acid product, however, necessitates the use of more stringent packaging techniques, and often requires refrigeration of the product at the point of sale. 
     Several packaging techniques, including extended shelf life (ESL) and aseptic packaging, have been developed to increase the shelf life of low acid products. During ESL packaging, for example, the packaging material is commonly sanitized and filled with a product in a presterilized tunnel under “ultra-clean” conditions. By using such ESL packaging techniques, the shelf life of an ESL packaged product is commonly extended from about 10 to 15 days to about 90 days. Aseptic packaging techniques, however, which require that the packaging take place in a sterile environment, using presterilized containers, etc., are capable of providing a packaged product having an even longer shelf life of 150 days or more. In fact, with aseptic packaging, the shelf life limitation is often determined by the quality of the taste of the packaged product, rather than by a limitation caused by bacterial growth. 
     For the aseptic packaging of food products, an aseptic filler must, for example, use an FDA (Food and Drug Administration) approved sterilant, meet FDA quality control standards, use a sterile tunnel or clean room, and must aseptically treat all packaging material. The food product must also be processed using an “Ultra High Temperature” (UHT) pasteurization process to meet FDA aseptic standards. The packaging material must remain in a sterile environment during filling, closure, and sealing operations. 
     Many attempts have been made, albeit unsuccessfully, to aseptically fill containers, such as bottles or jars having small openings, at a high output processing speed. In addition, previous attempts for aseptically packaging a low acid product in plastic bottles or jars (e.g., formed of polyethylene terepthalate (PET) or high density polyethylene (HDPE)), at a high output processing speed, have also failed. Furthermore, the prior art has not been successful in providing a high output aseptic filler that complies with the stringent United States FDA standards for labeling a packaged product as “aseptic.” In the following description of the present invention, the term “aseptic” denotes the United States FDA level of aseptic. 
     SUMMARY OF THE INVENTION 
     In order to overcome the above deficiencies, the present invention provides an apparatus and method for providing container product filling in an aseptic processing apparatus. Additionally, the present invention provides both a “Clean In Place” (CIP) process for cleaning, and a “Sterilizing in Place” for sterilizing all of the interior surfaces of the filler without having to disassemble the filler. The filler apparatus includes a smooth filling tube which is easy to clean and sterilize. The filler apparatus is used in a system for providing aseptically processed low acid products in a container having a small opening, such as a glass or plastic bottle or jar, at a high output processing speed. Many features are incorporated into the filler apparatus in order to meet various FDA aseptic standards and 3A Sanitary Standards and Accepted Practices. 
     The present invention generally provides an apparatus comprising: 
     a valve for controlling a flow of product; 
     a first sterile region surrounding a region where the product exits the valve; 
     a second sterile region positioned proximate said first sterile region; 
     a valve activation mechanism for controlling the opening or closing of the valve by extending a portion of the valve from the second sterile region into the first sterile region and by retracting the portion of the valve from the first sterile region back into the second sterile region. 
     The present invention generally provides a method comprising the steps of: 
     controlling a flow of product using a valve; 
     surrounding a region where the product exits the valve with a sterile region; 
     providing a second sterile region positioned proximate said first sterile region; and 
     controlling the opening or closing of the valve by extending a portion of the valve from the second sterile region into the first sterile region and by retracting the portion of the valve from the first sterile region back into the second sterile region. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The features of the present invention will best be understood from a detailed description of the invention and a preferred embodiment, thereof selected for the purposes of illustration, and shown in the accompanying drawings in which: 
     FIG. 1 is plan view of an aseptic processing apparatus in accordance with a preferred embodiment of the present invention; 
     FIG. 2 side view of the aseptic processing apparatus of FIG. 1; 
     FIG. 3 is a partial cross-sectional side view of the aseptic processing apparatus of FIG. 1; 
     FIG. 4 is a cross-sectional side view of a bottle infeed and sterilization apparatus; 
     FIG. 5 illustrates a cross-sectional top view of the bottle infeed and sterilization apparatus taken along line  5 — 5  of FIG. 4; 
     FIG. 6 is an interior sectional view of an interior wall taken along line  6 — 6  of FIG. 4; 
     FIG. 7 is a cross-sectional view of the bottle infeed and sterilization apparatus taken along line  7 — 7  of FIG. 4; 
     FIG. 8 is a perspective view of a conveying plate for use in the aseptic processing apparatus of the present invention; 
     FIG. 9 is a perspective view of a partition in a sterilization tunnel; 
     FIG. 10 is a cross-sectional side view of an interior bottle sterilization apparatus and the partition located between stations  8  and  9 ; 
     FIG. 11 is a cross-sectional side view of the partition located between stations  22  and  23 ; 
     FIG. 12 is a cross-sectional side view of the partition located between stations  35  and  36 ; 
     FIG. 13 is a cross-sectional side view of a lid sterilization and heat sealing apparatus; 
     FIG. 14 is a side view of a lifting apparatus with a gripper mechanism for lifting the bottles from the sterilization tunnel; 
     FIG. 15 is a top view of the aseptic processing apparatus; 
     FIG. 16 is a side view of the aseptic processing apparatus indicating the control and monitoring locations that are interfaced with a control system; 
     FIG. 17 is a plan view of a daisy chain of lids; 
     FIG. 18 is a plan view of another embodiment of a daisy chain of lids with holes for receiving pins of a drive wheel; 
     FIG. 19 is another embodiment of the lid sterilization and heat sealing apparatus including a pin drive apparatus; 
     FIG. 20 is perspective view of the heat sealing and gripper apparatus; 
     FIG. 21 is a schematic diagram of a sterilization control system for the interior bottle sterilization apparatus; 
     FIG. 22 is a side view of a main product filler apparatus; 
     FIG. 23 is a cross-sectional view of a valve in a closed position in a first sterile region; 
     FIG. 24 is a cross-sectional view with a portion of a valve stem displaced from a non-sterile region into the first sterile region; 
     FIG. 25 is a cross-sectional view of the valve in a closed position in a first sterile region, and with the portion of the valve stem located in a second sterile region; and 
     FIG. 26 is a cross-sectional view of the valve in an open position where the portion of the valve located in the second sterile region has been displaced into the first sterile region. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Although certain preferred embodiments of the present invention will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present invention will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of the preferred embodiment. The features and advantages of the present invention are illustrated in detail in the accompanying drawings, wherein like reference numerals refer to like elements throughout the drawings. Although the drawings are intended to illustrate the present invention, the drawings are not necessarily drawn to scale. 
     The present invention provides an aseptic processing apparatus  10  that will meet the stringent United States FDA (Food and Drug Administration) requirements and 3A Sanitary Standards and Accepted Practices required to label a food product (foodstuffs) as “aseptic.” Hereafter, “aseptic” will refer to the FDA level of aseptic. The present invention provides an aseptic processing apparatus  10  for producing at least about a 12 log reduction of  Clostridium botulinum  in food products. In addition, the present invention produces packaging material with at least about a 6 log reduction of spores. Actual testing of the aseptic processing apparatus is accomplished with spore test organisms. These test organisms are selected on their resistance to the media selected used to achieve sterility. For example, when steam is the media, the test organism is  Bacillus stearothermophilus.  When hydrogen peroxide is the media, then the test organism is  Bacillus subtilis  var.  globigii.    
     The present invention processes containers such as bottles or jars that have a small opening compared to its height and its greatest width (e.g., the ratio of the opening diameter to the height of the container is less than 1.0). In the preferred embodiment, a bottle  12  (see, e.g., FIG. 8) is illustrated as the container. The container may alternately comprise a jar. The bottle  12  is preferably formed of a plastic such as polyethylene terepthalate (PET) or high density polyethylene (HDPE), although other materials such as glass may also be used. The present invention uses an aseptic sterilant such as hydrogen peroxide (H 2 O 2 ) or oxonia (hydrogen peroxide and peroxyacetic acid) to sterilize the bottles  12 . In the preferred embodiment of the present invention, hydrogen peroxide is used as the sterilant. The present invention uses hydrogen peroxide with a concentration of less than about 35% and ensures that the bottles  12  have less than about 0.5 ppm of residual hydrogen peroxide after each bottle  12  is sterilized. 
     FIGS. 1-3 illustrate several views of an aseptic processing apparatus  10  in accordance with a preferred embodiment of the present invention. As shown, the aseptic processing apparatus  10  includes a first bottle unscrambler  20 , a second bottle unscrambler  30 , and a bottle lifter  40  for providing a supply of properly oriented empty bottles. The empty bottles are delivered to a filler apparatus  50  after passing through a bottle infeed and sterilization apparatus  60  for aseptic sterilization. The filled bottles are sealed at a first capping apparatus  400  or a second capping apparatus  410 . A control system  550  monitors and controls the operation of the aseptic processing apparatus  10 . The filled and sealed bottles are packed and palletized using a first case packing apparatus  480 , a second case packing apparatus  490 , a first palletizer  500 , and a second palletizer  510 . 
     The bottles  12  arrive at a first bottle unscrambler  20  with a random orientation, such that an opening  16  (see FIG. 8) of each bottle  12  can be oriented in any direction. The first bottle unscrambler  20  manipulates the bottles  12  until the opening  16  of each bottle  12  is in a top vertical position. The bottles  12  leave the first bottle unscrambler  20  in a series formation with the opening  16  of each bottle  12  oriented vertically. The bottles  12  travel in single file in a first lane  18  to a first bottle lifter  40 . The first bottle lifter  40  lifts and transports the bottles  12  to a bottle infeed and sterilization apparatus  60 . A second bottle unscrambler  30  may also used to provide a supply of vertically oriented bottles  12 . The bottles  12  output from the second bottle unscrambler  30  travel in single file in a second lane  22  to a second bottle lifter  42 , which lifts and transports the bottles  12  to the bottle infeed and sterilization apparatus  60 . 
     FIG. 3 illustrates the bottle infeed, sterilization, and conveying apparatus  60  attached to the filler apparatus  50 . FIG. 4 illustrates a cross-sectional side view of the bottle infeed, sterilization, and conveying apparatus  60 . FIG. 5 illustrates a cross-sectional top view of the bottle infeed, sterilization, and conveying apparatus  60  taken along line  5 — 5  of FIG.  4 . The bottle infeed and sterilization apparatus  60  preferably inputs six bottles  12  in a horizontal direction from the first lane  18  and six bottles in a horizontal direction from the second lane  22  (FIG.  5 ). A gate  76  in the first lane  18  selectively groups six bottles  12  at a time in first horizontal row  24 . A gate  78  in the second lane  22  selectively groups six bottles  12  at a time in a second horizontal row  28 . An infeed apparatus  80  includes a pushing element  84  for pushing the bottles  12  in the first horizontal row  24  into a first vertical lane  26 . A corresponding infeed apparatus  80  includes a pushing element  86  for pushing the bottles  12  in the second horizontal row  28  into a second vertical lane  32 . The six bottles  12  in the first vertical lane  26  and the six bottles  12  in the second vertical lane  32  are directed downward into the bottle infeed and sterilization apparatus  60 . 
     Referring to FIG. 4, as the bottles  12  move downward in the first vertical lane  26  and the second vertical lane  32 , a sterilant  14 , such as heated hydrogen peroxide, oxonia, or other aseptic sterilant, is applied to an outside surface  34  of each bottle  12  by a sterilant application apparatus  36 . The outside surface  34  of a bottle  12  is illustrated in greater detail in FIG.  8 . The bottles  12  may move downward in the first vertical lane  26  and the second vertical lane  32  by the force of gravity. Alternatively, controlled downward movement of the bottles  12  can be created by the use of a conveying device such as a moving conveying chain. A plurality of pins are attached to the conveying chain. Each bottle  12  rests on one of the pins attached to the conveying chain. Therefore, the motion of each bottle is controlled by the speed of the moving conveying chain. 
     A sterilant such as hydrogen peroxide may be provided to the sterilant application apparatus  36  in many ways. For example, liquid hydrogen peroxide may be provided in a reservoir at a level maintained by a pump and overflow pipe. A plurality of measuring cups (e.g., approximately 0.5 ml each) connected by an air cylinder are submerged into the reservoir and are lifted above the liquid level. Thus, a measured volume of liquid hydrogen peroxide is contained in each measuring cup. 
     Each measuring cup may include a conductivity probe that is configured to send a signal to the control system  550  indicating that the measuring cup is full. A tube (e.g., having a diameter of about {fraction (1/16)}″) is positioned in the center of the measuring cup. A first end of the tube is positioned near the bottom of the measuring cup. A second end of the tube is connected to the sterilant application apparatus  36 . The sterilant application apparatus  36  includes a venturi and a heated double tube heat exchanger. When the measuring cup is full, and a signal is received from the control system  550 , a valve is opened allowing pressurized sterile air to enter the venturi. The pressurized air flow causes a vacuum to be generated in second end of the tube causing liquid hydrogen peroxide to be pulled out of the measuring cup. The liquid hydrogen peroxide is sprayed into a sterile air stream which atomizes the hydrogen peroxide into a spray. The atomized hydrogen peroxide enters the double tube heat exchanger in order to heat the atomized hydrogen peroxide above its vaporization phase. The double tube heat exchanger is heated with steam and the temperature is monitored and controlled by the control system  550 . In FIG. 4, the application of the sterilant  14  by the sterilant application apparatus  36  is accomplished through the use of spray nozzles  64  that produce a sterilant fog which is directed to the entire outside surface  34  of each bottle  12 . 
     Alternatively, a direct spray of heated hydrogen peroxide may be continuously applied to the outside surface  34  of each bottle  12 . For producing the direct spray, a metering pump regulates the amount of hydrogen peroxide, a flow meter continuously measures and records the quantity of hydrogen peroxide being dispensed, a spray nozzle produces a fine mist, and a heat exchanger heats the hydrogen peroxide above the vaporization point. 
     FIGS. 3 and 4 illustrate the sterilization chamber  38  for activation and drying of bottles  12  which is included in the bottle infeed, sterilization, and conveying apparatus  60 . The sterilization chamber  38  sterilizes the outside surface  34  of each bottle  12 . The sterilization chamber  38  encloses a conduit  39 . Sterile heated air, which is generated by a sterile air supply system  146  (FIG.  3 ), enters the conduit  39  of the sterilization chamber  38  through ports  67  and  68  located at the bottom of the sterilization chamber  38 . The sterile heated air also enters through a bottom opening  62  of the bottle infeed and sterilization apparatus  60 . The sterile heated air travels up through the conduit  39  of the sterilization chamber  38 , and exits the top of the sterilization chamber  38  through an exhaust conduit  70 . The sterile heated air continuously flows in an upward direction through the sterilization chamber  38 , thus preventing any contaminants from entering the bottle infeed and sterilization apparatus  60 . To create the sterile heated air, the air is first passed through a filtering system (e.g., a group of double sterile air filters to sterilize the air. The air is then heated in a heating system (e.g., an electric heater) to about 230° F. The air temperature is regulated by the control system  550 . Other techniques for providing the sterile heated air may also be used. The control system  550  monitors the air pressure and flow rate of the sterile heated air to ensure that an adequate flow of the hot sterile air is maintained in the bottle sterilization chamber  38  of the bottle infeed and sterilization apparatus  60 . 
     As illustrated in FIGS. 4,  6 , and  7 , the sterilization chamber  38  includes two opposing, interior, perforated walls  72 A,  72 B. The perforated walls  72 A and  72 B guide the bottles  12  downward in the first vertical lane  26  and the second vertical lane  32 , respectively. The perforated walls  72 A,  72 B also allow the complete circulation of hot sterile air around the outside surface  34  of each bottle  12  in the sterilization chamber  38 . The sterilization chamber  38  supplies hot sterile air to the outside surface  34  of each bottle  12  between the sterilant application apparatus  36  and the bottom opening  62  of the bottle infeed and sterilization apparatus  60 . This sterilant may be hydrogen peroxide or oxonia (hydrogen peroxide and peroxyacetic acid). 
     In accordance with the preferred embodiment of the present invention, twelve drying positions are provided in the sterilization chamber  38 . Each bottle  12  is exposed to the hot sterile air in the sterilization chamber  38  for about at least 24 seconds. This provides time sufficient time for the hydrogen peroxide sterilant to break down into water and oxygen, to kill any bacteria on the bottles  12 , and to evaporate from the outside surface  34  of the bottles  12 . 
     An exhaust fan  73  is located at a top of the exhaust conduit  70  to provide an outlet from the sterilization tunnel  90 , and to control the sterile air flow rate through the sterilization chamber  38 . The exhaust fan  73  is controlled by the control system  550 . The control system  550  controls the sterile air temperature preferably to about 230° F., and controls the sterile air flow rate through the sterilization chamber  38 . The flow rate is preferably about 1800 scfm through the sterilization chamber  38 . The bottles  12  leave the sterilization chamber  38  with a hydrogen peroxide concentration of less than 0.5 PPM. 
     As shown in FIGS. 3 and 4, a plurality of proximity sensors  71  located along the sides of the vertical lanes  26 ,  32  detect any bottle  12  jams that occur within the sterilization chamber  38 . The proximity sensors  71  transmit an alarm signal to the control system  550 . The bottles  12  leave the bottle infeed and sterilization apparatus  60  through the bottom opening  62 , and enter a sterilization tunnel  90  of the filler apparatus  50 . 
     In the preferred embodiment of the present invention, the filler apparatus  50  includes forty-one (41) index stations  92 , hereafter referred to as “stations.” Various index stations  92  are illustrated in FIGS. 3,  4 , and  11 - 15 . The conveying motion of the bottles  12  to the various stations  92  through the filler apparatus  50  is based on an indexing motion. The filler apparatus  50  is designed to convey the bottles  12  through the various operations of the filler  50  in a two by six matrix. The twelve bottles  12  in the two by six matrix are positioned in, and displaced by, a conveying plate  94  as illustrated in FIG.  8 . Therefore, twelve bottles  12  are exposed to a particular station  92  at the same time. A conveying apparatus  100  moves the set of twelve bottles  12  in each conveying plate  94  sequentially through each station  92 . 
     Referring to FIGS. 3 and 4, the bottles  12  are supplied from an infeed chamber  102  to station  2  of the filler apparatus  50  through the bottom opening  62  of the bottle infeed and sterilization apparatus  60 . The infeed chamber  102  is enclosed to direct heated hydrogen peroxide laden air completely around the outer surface  34  of the bottles  12 . A mechanical scissors mechanism and a vacuum “pick and place” apparatus  104  position twelve bottles  12  at a time (in a two by six matrix, FIG. 8) into one of the conveying plates  94 . 
     A plurality of conveying plates  94  are attached to a main conveyor  106 . The main conveyor  106  forms a continuous element around conveyor pulleys  108  and  110  as illustrated in FIG. 3. A bottle support plate  107  supports a bottom  120  of each bottle  12  as the bottles  12  are conveyed from station to station through the filler apparatus  50 . Each conveying plate  94  passes through stations  1  through  41 , around pulley  108 , and returns around pulley  110  to repeat the process. The main conveyor  106 , conveying plates  94 , and pulleys  108  and  110  are enclosed in the sterilization tunnel  90 . 
     At station  4 , the bottles  12  in the conveying plate  94  enter a bottle detection apparatus  112 . The bottle detection apparatus  112  determines whether all twelve bottles  12  are actually present and correctly positioned in the conveying plate  94 . Proximity sensors  114  detect the presence and the alignment of each bottle  12 . In the present invention, a bottle  12  with correct alignment is in an upright position with the opening  16  of the bottle  12  located in an upward position. Information regarding the location of any misaligned or missing bottles  12  is relayed to the control system  550 . The control system  550  uses this location information to ensure that, at future stations  92 , bottle filling or sealing will not occur at the locations corresponding to the misaligned or missing bottles  12 . 
     At station  7 , as illustrated in FIGS. 3 and 10, the bottles  12  in the conveying plate  94  enter an interior bottle sterilization apparatus  116 . A sterilant, such as hydrogen peroxide, oxonia, or any other suitable aseptic sterilant is applied as a heated vapor fog into the interior  118  of each bottle  12 . Preferably, hydrogen peroxide is used as the sterilant in the present invention. The application of sterilant is accomplished with the use of a plurality of sterilant measuring devices  121  and a plurality of probes  123 . Each probe  123  includes any practical means for transferring the sterilant from the probe  123  to the interior surface  119  of the bottle  12 . For example, an opening or a plurality of openings may be used for ejecting the sterilant onto the interior surface  119 . Preferably, in the present invention, an applicator spray nozzle  122  is included in each probe  123 . The applicator spray nozzle  122  provides uniform sterilant application without droplet formation on the interior surface  119  of the bottle  12 . A separate measuring device  121  and the probe  123  are used for each of the twelve bottle  12  locations in the conveying plate  94 . Each sterilant measuring device  121  may include a spoon dipper  304  (e.g., approximately 0.5 ml each) as illustrated in FIG.  21 . Each bottle  12  is supplied with the same measured quantity of sterilant, preferably in the form of a hot vapor fog. A pump  306  provides a sterilant (e.g., hydrogen peroxide) from a sterilant supply tank  310  to a reservoir  124 . An overflow pipe  308  maintains the sterilant liquid level in the reservoir  124  by returning excess sterilant to the sterilant supply tank  310 . The spoon dipper  304  connected to an air cylinder  316  is submerged into the reservoir  124  and is lifted above the liquid level. Thus, a measured volume of liquid hydrogen peroxide (e.g., approximately 0.5 ml) is contained in each spoon dipper  304 . 
     Each spoon dipper  304  may include a conductivity probe that is configured to send a signal to the control system  550  indicating that the spoon dipper  304  is full. A tube  312  (e.g., having a diameter of about {fraction (1/16)}″) is positioned in the center of the spoon dipper  304 . A first end of the tube  312  is positioned near the bottom of the spoon dipper  304 . A second end of the tube  312  is connected to an atomizing venturi  314 . 
     A pressurized air source  318  is connected by a conduit  320  to a flow adjust valve  322 . A conduit  324  connects the flow adjust valve  322  to a regulator valve  326 . A conduit  328  connects the regulator valve  326  with a solenoid actuated valve  330 . A conduit  332  connects the solenoid actuated valve  330  with the air cylinder  316 . The control system  550  controls the solenoid actuated valve  330  which controls the compressed air supplied to the air cylinder  316 . Compressed air supplied to the air cylinder  316  lowers or lifts the spoon dipper  304  into or out of the liquid sterilant. 
     A conduit  334  connects the flow adjust valve  322  with the regulator valve  336 . A conduit  338  connects the regulator valve  336  with a sterile air filter  340 . A conduit  342  connects the sterile air filter  340  with a solenoid actuated valve  344 . A conduit  346  connects the solenoid actuated valve  344  with the atomizing venturi  314 . When the spoon dipper  304  is full, and a signal is received from the control system  550 , the solenoid actuated valve  344  is opened allowing pressurized sterile air to enter the atomizing venturi  314  through the conduit  346 . The pressurized air flow causes a vacuum to be generated in the second end of the tube  312  causing liquid hydrogen peroxide to be pulled out of the spoon dipper  304 . 
     A first supply of sterile air is supplied through conduit  346 . The pressurized air supplied through conduit  346  is used to atomize the hydrogen peroxide sterilant in the atomizing venturi  314 . Atomization of the liquid hydrogen peroxide may be provided by other means such as by using ultrasonic frequencies to atomize the liquid hydrogen peroxide. 
     A conduit  348  connects with the atomizing venturi  314 , passes through a heat exchanger  350  (e.g., double tube heat exchanger), and connects with a probe  123  including the applicator spray nozzle  122 . A conduit  352  connects a steam supply  354  with a valve  356 . A conduit  358  connects the valve  356  with a regulator valve  360 . A conduit  382  connects the regulator valve  360  with the heat exchanger  350 . 
     A second supply of hot sterile air is supplied to the atomized sterilant through a conduit  378 . A humidity control apparatus  362  maintains the humidity level of the air entering a blower  364 . A conduit  366  connects the blower  364  with a heater  368 . A conduit  370  connects the heater  368  with a sterile filter  372 . A conduit  374  connects the sterile filter  372  with a flow adjust valve  376 . The conduit  378  connects the flow adjust valve  376  with the conduit  348 . A conduit  380  connects the sterile filter  372  with a bypass valve  382 . The blower  364  operates continuously supplying humidity controlled air to the heater  368 . The flow of heated sterile air is controlled with the flow adjust valve  376  and travels through conduit  378 . 
     Exiting conduit  378 , the second supply of hot sterile air enters the conduit  348  to mix with the atomized hydrogen peroxide from the atomizing venturi  314 . Excess flow of heated sterile air travels through conduit  380  and passes through the bypass valve  382 . The second supply of hot sterile air assists in obtaining a uniform concentration of hydrogen peroxide in the air stream in conduit  348  and provides enough momentum to ensure that all portions of the bottle  12  interior  118  are contacted by hydrogen peroxide. Furthermore, the second supply of hot sterile air is continuously blowing, whereas the first supply of sterile air and hydrogen peroxide in conduit  346  is intermittent corresponding to the movement of the bottles  12 . Since the second supply of hot sterile air is continuous, hydrogen peroxide does not have the ability to fall out of the air stream and deposit in the delivery conduit  348  in the form of drops. This ensures that the delivery of hydrogen peroxide is consistent from one bottle  12  application to the next and does not allow a drop to be directed into the bottle  12  interior  118 . 
     The mixture of heated sterile air and atomized hydrogen peroxide in conduit  348  passes through the double tube heat exchanger  350 . The double tube heat exchanger  350  adds additional heat to the atomized hydrogen peroxide. Heat is supplied to the double tube heat exchanger  350  from the steam supply  354  controlled by the regulator valve  360 . Generally, hydrogen peroxide has chemical stabilizers in it that may cause a white powder precipitate to form on the inner surfaces of the double tube heat exchanger  350 . This occurs when the temperature differential between the supplied steam heat and the gas to be heated is large. In the present invention, the temperature of the atomized hydrogen peroxide is typically about the same as the supplied steam heat so that a minimal amount of precipitate occurs. Another embodiment of the invention eliminates the need for the double tube heat exchanger  350  because the temperature of the atomized hydrogen peroxide is already at the desired temperature. 
     The temperature of the atomized gas entering the interior  118  of the bottle  12  is in the range of about 100° C. to 120° C. This temperature is limited to prevent the plastic bottles  12  from melting. The droplet size occurring on the interior surface  119  of the bottles  12  is in the range of about 300 to 500 micrometers. The initial concentration level of hydrogen peroxide on the interior surface  119  of the bottle  12  is about 35%. 
     As illustrated in FIG. 21, the control system  550  monitors the temperatures at locations denoted as “T” in the interior bottle sterilization apparatus  116 . The temperartures “T” are measured in the conduit  348 , in the heater  368 , and in the conduit  370 . Additionally, the control system  550  monitors the pressures at locations denoted as “P” as illustrated in FIG.  21 . The pressures “p” are measured in the conduit  328 , conduit  338 , and in the conduit  382 . 
     The control system  550  monitors and controls a spray apparatus  126  that includes the probe  123  including the applicator spray nozzles  122  FIG.  10 . Each applicator spray nozzle  122  sprays the sterilant into the interior  118  of a corresponding bottle  12  as a hot vapor fog. The probe  123  including applicator spray nozzles  122  are designed to extend through the bottle openings  16 . The probe  123  including applicator spray nozzles  122  descends into the interior  118  and toward the bottom of the bottles  12 . This ensures the complete application of sterilant to the entire interior  118  and interior surface  119  of each bottle  12 . Alternately, the probe  123  including the applicator spray nozzles  122  may be positioned immediately above the bottle openings  16  prior to the application of sterilant. 
     FIG. 9 illustrates a perspective view of a partition  130  that provides control of sterile air flow within the sterilization tunnel  90  of the filler apparatus  50 . The partition  130  includes a top baffle plate  132 , a middle baffle plate  134 , and a bottom baffle plate  136 . The top baffle plate  132  and the middle baffle plate  134  are provided with cut-outs  133  which correspond to the outer shape of each bottle  12  and to the outer shape of the conveyor plate  94 . The cut-outs  133  allow each bottle  12  and each conveyor plate  94  to pass through the partition  130 . A space  138  between the middle baffle plate  134  and the bottom baffle plate  136  allows each empty conveyor plate  94  to pass through the partition  130  as it travels on its return trip from the pulley  108  toward the pulley  110 . 
     As illustrated in FIG. 3, partitions  130 A,  130 B, and  130 C, are located within the sterilization tunnel  90 . FIG. 10 illustrates a cross-sectional view of partition  130 A including baffle plates  132 A,  134 A, and  136 A. The partition  130 A is located between stations  8  and  9 . FIG. 11 illustrates a cross-sectional view of partition  130 B including baffle plates  132 B,  134 B, and  136 B. The partition  130 B is located between stations  22  and  23 . FIG. 12 illustrates a cross-sectional view of partition  130 C including baffles  132 C,  134 C, and  136 C. The partition  130 C is located between stations  35  and  36 . As illustrated in FIG. 3, sterile air is introduced through sterile air supply sources (e.g., conduits  140 ,  142 , and  144 ) into the sterilization tunnel  90 . The sterile air conduit  140  is located at station  23  (FIG.  11 ), the sterile air conduit  142  is located at station  27  (FIG.  3 ), and the sterile air conduit  144  is located at station  35  (FIG.  12 ). 
     The partition  130 A separates an activation and drying apparatus  152  from the interior bottle sterilization apparatus  116 . The partition  130 B separates the activation and drying apparatus  152  from a main product filler apparatus  160  and a lid sterilization and heat sealing apparatus  162 . Thus, a first sterilization zone  164  is created that includes the activation and drying apparatus  152 . Partition  130 C separates the main product filler apparatus  160  and the lid sterilization and heat sealing apparatus  162  from a bottle discharge apparatus  280 . Thus, partitions  130 B and  130 C create a second sterilization zone  166  that includes the main product filler apparatus  160  and the lid sterilization and heat sealing apparatus  162 . A third sterilization zone  172  includes the bottle discharge apparatus  280 . A fourth sterilization zone  165  includes the interior bottle sterilization apparatus  116 . The second sterilization zone  166  provides a highly sterile area where the bottles  12  are filled with a product and sealed. The second sterilization zone  166  is at a higher pressure than the first sterilization zone  164  and the third sterilization zone  172 . Therefore, any gas flow leakage is in the direction from the second sterilization zone  166  out to the first sterilization zone  164  and the third sterilization zone  172 . The first sterilization zone  164  is at a higher pressure than the fourth sterilization zone  165 . Therefore, gas flow is in the direction from the first sterilization zone  164  to the fourth sterilization zone  165 . 
     The partitions  130 A,  130 B, and  130 C create sterilization zones  164 ,  165 ,  166 , and  172  with different concentration levels of gas laden sterilant (e.g., hydrogen peroxide in air). The highest concentration level of sterilant is in the fourth sterilization zone  165 . For example, with the sterilant hydrogen peroxide, the concentration level of hydrogen peroxide is about 1000 ppm (parts per million) in the fourth sterilization zone  165 . The hydrogen peroxide sterilant level is about 3 ppm in the first sterilization zone  164 . The lowest concentration level of sterilant is in the second sterilization zone  166 . In the second sterilization zone  166 , the hydrogen peroxide sterilant concentration level is less than 0.5 ppm and typically about 0.1 ppm. Advantageously, this helps to maintain the main product filler apparatus  160  and the lid sterilization and heat sealing apparatus  162  at a low sterilant concentration level. This prevents unwanted high levels of sterilant to enter the food product during the filling and lidding process. The hydrogen peroxide sterilant concentration level is about 0.1 ppm in the third sterilization zone  172 . 
     As illustrated in FIG. 3, a gas such as hot sterile air enters the first sterilization zone  164  at a rate of about 2400 cfm (cubic feet per minute). The temperature of the hot sterile air is about 230° F. The hot sterile air enters the first sterilization zone  164  through conduit  148 . Additional hot sterile air enters the second sterile zone through sterile air conduits  140 ,  142 , and  144  at a total rate of about 1000 cfm (FIG.  3 ). Also, hot sterile air enters at a rate of about 1800 cfm through ports  67  and  68  leading into the infeed and sterilization apparatus  60 . A portion of the hot sterile air exits the sterilization tunnel  90  at a rate of about 1500 cfm through a plurality of exhaust ports  153  located in the first sterilization zone  164  (FIG.  15 ). A portion of the hot sterile air exits the sterilization tunnel  90  at a rate about 100 cfm through an opening  282  (FIG.  14 ). The bottles  12  exit the sterilization tunnel  90  through the opening  282 . The continuous flow of sterile air flow out through the opening  282  prevents contaminants from entering the sterilization tunnel  90 . 
     As illustrated in FIG. 3, the hot sterile air is drawn out of the fourth sterilization zone  165  of the sterilization tunnel  90  through the bottom opening  62  in the bottle infeed and sterilization apparatus  60 . Next, the hot sterile air from the infeed and sterilization apparatus together with the fourth sterilization zone  165  exits out of the exhaust conduit  70  of the infeed and sterilization apparatus at a rate of about 3600 cfm. This outflow of hot sterile air from the bottle infeed and sterilization apparatus  60  prevents contaminants from entering the bottle infeed sterilization apparatus  60  and the sterilization tunnel  90 . 
     Stations  10  through  21  include twelve stations for directing hot sterile air into each bottle  12  for the activation and removal of the sterilant from the interior of the bottle  12 . In these twelve stations, a third supply of hot sterile air is provided through the sterile air supply system  146 . The sterile air supply system  146  supplies hot sterile air to a plurality of nozzles  150  in the activation and drying apparatus  152 . The hot sterile air flow in each bottle  12  is about 40 SCFM. Hot sterile air is supplied to the sterile air supply system  146  through conduit  148 . The air is first passed through a filtration system to sterilize the air. The air is then heated in a heating system to about 230° F. The air temperature is regulated by the control system  550 . Also, the control system  550  monitors the air pressure and flow rate to ensure that an adequate flow of hot sterile air is maintained in the sterilization tunnel  90  of the application and drying apparatus  152 . 
     As shown in FIG. 8, each bottle  12  generally has a small opening  16  compared to its height “H.” A ratio of a diameter “D” of the bottle  12  to the height “H” of the bottle  12  is generally less than 1.0. The small bottle opening  16  combined with a larger height “H” restricts the flow of hot gas into the interior  118  of the bottle  12 . Also, PET and HDPE bottle materials have low heat resistance temperatures. These temperatures commonly are about 55° C. for PET and about 121° C. for HDPE. Typically, in the aseptic packaging industry, a low volume of air at a high temperature is applied to the packaging materials. This often results in deformation and softening of packaging materials formed of PET and HDPE. In order to prevent softening and deformation of the bottles  12 , when formed from these types of materials, the present invention applies high volumes of air at relatively low temperatures over an extended period of time in the activation and drying apparatus  152 . The plurality of nozzles  150  of the activation and drying apparatus  152  direct hot sterile air into the interior  118  of each bottle  12  (FIG.  11 ). A long exposure time is predicated by the geometry of the bottle  12  and the softening temperature of the material used to form the bottle  12 . In the present invention, about 24 seconds are allowed for directing hot sterile air from the plurality of nozzles  150  into each bottle for the activation and removal of sterilant from the interior surface  119  of the bottle  12 . To achieve aseptic sterilization, a minimum bottle temperature of about 131° F. should be held for at least 5 seconds. To achieve this bottle temperature and time requirements, including the time required to heat the bottle, the sterilant is applied for about 1 second and the hot sterile air is introduced for about 24 seconds. The hot sterile air leaves the nozzles  150  at about 230° F. and cools to about 131° F. when it enters the bottle  12 . The hot sterile air is delivered at a high volume so that the bottle  12  is maintained at about 131° F. for at least 5 seconds. The about 24 seconds provides adequate time for the bottle  12  to heat up to about 131° F. and to maintain this temperature for at least 5 seconds. After bottle  12  has dried, the residual hydrogen peroxide remaining on the bottle  12  surface is less than 0.5 PPM. 
     A foodstuff product is first sterilized to eliminate bacteria in the product. An “Ultra High Temperature” (UHT) pasteurization process is required to meet the aseptic FDA standard. The time and temperature required to meet the aseptic FDA standard depends on the type of foodstuff. For example, milk must be heated to 282° F. for not less than 2 seconds in order to meet the aseptic standards. 
     After UHT pasteurization, the product is delivered to a main product filler apparatus  160 . The main product filler apparatus is illustrated in FIGS. 3,  13 , and  22 . The main product filler  160  can be sterilized and cleaned in place to maintain aseptic FDA and 3A standards. A pressurized reservoir apparatus  180  that can be steam sterilized is included in the main product filler apparatus  160 . As illustrated in FIG. 22, the pressurized reservoir apparatus  180  includes an enclosed product tank  182  with a large capacity (e.g., 15 gallons). The product tank  182  is able to withstand elevated pressures of about 60 psig or more. The pressurized reservoir apparatus  180  also includes a level sensor  184 , a pressure sensor  186 , at least one volumetric measuring device  188  (two are shown as  188 A,  188 B), and at least one filling nozzle  190  (two are shown as  190 A,  190 B). The product tank  182  includes a single product inlet  250  with a valve cluster (not shown) including a sterile barrier to separate the product supply system (not shown) from the main product filler apparatus  160 . The product tank  182  has an outlet with twelve connections. At each connections is a volumetric measuring device  188  such as a mass or volumetric flow meter. Pressurized steam or sterile air is supplied into the product tank  182  through the inlet  252 . The product level  254  in the product tank  182  is measured by the level sensor  184 . The control system  550  maintains the product level and pressure in the product tank  182 . This supplies each filling nozzle  190  (e.g.  190 A,  190 B) with a constant pressure that ensures proper product delivery to the bottles  12 . 
     Filling nozzles  190 A,  190 B are provided at stations  23 ,  25 , respectively. Additionally, there are a plurality of corresponding volumetric measuring devices  188 A and  188 B to measure the volume of product entering each bottle  12  at stations  23  and  25 , respectively. In accordance with the present invention, the volumetric measuring devices  188 A and  188 B are preferably electronic measuring devices such as a magnetic flow meter which measures the volume of product flow, or a mass flow meter which measures the weight of product flow. The electronic measuring devices provide filling accuracies of about 0.5%. The control system  550  calculates the desired volume of product to be inserted into each bottle  12 , and controls the product volume by opening or closing a plurality of valves  194 A and  194 B included in the filling nozzles  190 A and  190 B, respectively. The amount of product delivered to the bottles  12  is controlled by the duration of time that the plurality of valves  194 A and  194 B are open. The control system  550  controls the duration of time. Thus, any desired quantity of product may be selected by controlling the duration of time that the valves  194 A and  194 B are open. 
     The activation mechanisms for valves  194 A and  194 B include valve stems  256 A and  256 B attached to actuators  258 A and  258 B, respectively. Each actuator  258 A,  258 B may include any suitable actuating apparatus (e.g. hydraulic, pneumatic, electrical, etc.). Preferably, in the present invention, the actuators  258 A and  258 B include air cylinders controlled by the control system  550 . The actuators  258 A and  258 B are attached to the valve stems  256 A and  256 B, respectively. The actuators  258 A and  258 B displace the valve stems  256 A and  256 B in an upward and downward direction. 
     FIG. 23 illustrates the valve stem  256 A attached to the valve  194 A. A first sterile region  260  surrounds the nozzle  196 A through which product  262 A exits. The first sterile region  260  is connected to, and is at the same sterilization level as, the second sterilization zone  166  (FIG. 3) of the sterile tunnel  90 . The valve  194 A is in a closed position against nozzle  196 A blocking the flow of product  262 A into a bottle  12  (not shown) located in the first sterile region  260 . A first portion  264 A of the valve stem  256 A is surrounded by a non-sterile region  268 , for example, the area located outside of the sterile tunnel  90 . Thus, the first portion  264 A of the valve stem  256 A is exposed with contaminants. 
     As illustrated in FIG. 24, the actuator  258 A has displaced the valve stem  256 A in a downward direction. The valve  194 A is removed from the nozzle  196 A allowing product  262 A to flow into a bottle  12  (not shown). The first portion  264 A of the valve stem  256 A has entered the first sterile region  260 . This may create a problem because the first portion  264 A of the valve stem  256 A may carry contaminants from the non-sterile region  268  into the first sterile region  260 . In order to overcome this difficulty, the present invention has introduced a second sterile region  270  as illustrated in FIG.  25 . 
     The second sterile region  270 A is enclosed by a housing  272  and by a wall  274 . The wall  274  separates the second sterile region  270 A from the first sterile region  260 . The first sterile region  260  is connected to, and is at the same sterilization level, as the second sterilization zone  166  of the sterile tunnel  90 . A sterilizing media  424  is supplied to the second sterile region  270 A through the inlet conduit  420 A. An outlet conduit  422 A may be added to allow the sterilizing media  424  to leave the second sterile region  270 A. The sterilizing media  424  may include any suitable sterilant (e.g. steam, hydrogen peroxide, oxonia, etc.). The non-sterile region  268  lies outside of the housing  272 . A second portion  266 A of the valve stem lies in the non-sterile region  268 . As illustrated in FIG. 25, the valve  194 A is in a closed position against the nozzle  196 A blocking the flow of product  262 A into a bottle  12  (not shown) in the first sterile region  260 . The first portion  264 A of the valve stem  256 A is surrounded by the second sterile region  270 A. Thus, the first portion  266 A of the valve stem  256 A is maintained in a sterile condition. 
     As illustrated in FIG. 26, the actuator  258 A has displaced the valve stem  256 A in a downward direction. The valve  194 A is removed from the nozzle  196 A allowing product  262 A to flow into a bottle  12  (not shown). The first portion  264 A of the valve stem  256 A has entered the first sterile region  260 . In the present invention, the first portion  264 A of the valve stem  256 A has not introduced contaminants into the first sterile region  260  because the first portion  264 A of the valve stem  256 A was pre-sterilized in the second sterile region  270 A before entering the first sterile region  260 . The second portion  266 A of the valve stem  256 A has entered the second sterile region  270 A from the non-sterile region  268 . The second portion  266 A of the valve stem  256 A is sterilized in the second sterile region  270 A removing any contaminants. Therefore, the second sterile region  270 A removes any contaminants from the valve stem  256 A before any portion of the valve stem  256 A enters the first sterile region  260 . Thus, contaminants are prevented from entering the sterile tunnel  90  through the filling nozzles  190 A and  190 B, and the valves  194 A and  194 B, respectively. 
     The plurality of valves  194 A control the volume of product flowing through a corresponding plurality of nozzles  196 A into the bottles  12  at station  23 . The plurality of valves  194 B control the volume of product flowing through a corresponding plurality of nozzles  196 B into the bottles  12  at station  25 . The control system  550  uses previously stored information provided by the bottle detection apparatus  112  to only allow filling to occur at the locations where bottles  12  are actually present and correctly aligned. 
     The initial sterilization process for the pressurized reservoir apparatus  180  includes the step of exposing all of the surfaces of the pressurized reservoir apparatus  180  that come in contact with the product to steam at temperatures above about 250° F. for a minimum of about 30 minutes. Elements such as cups  198 A and  198 B (FIG. 22) are used to block off nozzle outlets  196 A and  196 B, respectively, to allow a build-up of steam pressure to about 50 psig inside the pressurized reservoir apparatus  180 . Condensate generated as the steam heats the interior surfaces of the pressurized reservoir apparatus  180  is collected in the cups  198 A and  198 B. This condensate is released when the cups  198 A and  198 B are removed from the nozzle outlets  196 A and  196 B. Once the interior surfaces of the pressurized reservoir apparatus  180  are sterilized, the steam is shut off, and sterile air is used to replace the steam. The sterile air reduces the interior temperature of the pressurized reservoir apparatus  180  to the temperature of the product before the product is allowed to enter the enclosed product tank  182 . As shown in FIG. 13, sterile air is directed through sterile air conduits  142  and  144  into the second sterilization zone  166  at a volume rate of about 800 scfm. The sterile air flow entering the second sterilization zone  166  provides sterile air to the main product filler apparatus  160  and to the lid sterilization and heat sealing apparatus  162 . 
     The main product filler apparatus  160  includes a separate filling position for each bottle. A bottle  12  moves into position under a nozzle  196 . The bottle stops and the valve  194  opens allowing product  262  to enter the bottle  12 . The volumetric measuring device  188  measure the amount of product entering the bottle  12 . Next, when the desired bottle  12  fill level is achieved, the valve  194  is closed. The control system  550  controls the valve opening and closing. Additionally, the control system  550  does not allow product  262  to flow if a bottle  12  is not present. The bottle  12  filling operation is completed for six bottles at station  23  and for six bottles at station  25 . The filling cycle is repeated for each cycle of the aseptic processing apparatus  10 . In the present invention the bottle filling time is about 1.5 seconds. Another embodiment of the present invention adds a second main product filler apparatus  160 B located at, for example, stations  27  and  29  (FIG.  22 ). In this embodiment, the bottles  12  are partially filled by the first main product filler apparatus  160  at stations  23  and  25 . Next, the bottles are moved to the second main product filler apparatus  160 B where the filling of each bottle is completed at stations  27  and  29 . For example, in filling each  16  fluid ounce bottle  12 , the first main product filler apparatus  160  would fill the first 8 ounces in about 1.5 seconds. Next, the second main product filler apparatus  160  would fill the remaining 8 ounces in each bottle  12  in another about 1.5 seconds. The second main product filler  160 B allows the operation to be kept to about 1.5 seconds at each main product filler apparatus  160 ,  160 B. This allows the conveying apparatus  100  to move the bottles through the aseptic processing apparatus  10  at speeds greater than about 350 bottles  12  per minute. 
     FIGS. 3,  13 ,  16  and  19  illustrate the lid sterilization and heat sealing apparatus  162 . A lid  200  is applied to each of the twelve bottles  12  at station  33 . For a fully aseptic bottle filler, complete lid  200  sterilization is necessary, and therefore a sterilant such as hydrogen peroxide is typically used. In the present invention, the lids are formed of a material such as foil or plastic. The lids  200  are joined together by a small interconnecting band  203  that holds them together to form a long continuous chain of lids  200 , hereinafter referred to as a “daisy chain”  202 . The daisy chain  202  of lids is illustrated in FIGS. 17. A daisy chain  202  of lids  200  is placed on each of a plurality of reels  210 . For the twelve bottle configuration of the present invention, six of the reels  210 , each holding a daisy chain  202  of lids  200 , are located on each side of a heat sealing apparatus  214 . Each daisy chain  202  of lids  200  winds off of a corresponding reel  210  and is sterilized, preferably using a hydrogen peroxide bath  204 . The concentration of hydrogen peroxide can range from about 30 to 40%, however, preferably the concentration is about 35%. Each lid  200  remains in the hydrogen peroxide bath  204  for at least about 6 seconds. A plurality of hot sterile air knives  208 , which are formed by jets of hot sterile air, activate the hydrogen peroxide to sterilize the lids  200  on the daisy chain  202 . The hot sterile air temperature is about 135° C. The hot air knives  208  also remove excess hydrogen peroxide from the lids  200 . A plurality of heated platens  205  further dry the lids  200  so that the residual concentration of hydrogen peroxide is less than 0.5 PPM. The hydrogen peroxide bath  204  prevents any contaminants from entering the sterilization tunnel  90  via the lidding operation. 
     Once sterilized, the lids  200  enter the sterilization tunnel  90  where they are separated from the daisy chain  202  and placed on a bottle  12 . Each lid is slightly larger in diameter then that of the opening  16  of a bottle  12 . During the placement of the lid  200  on the bottle  12 , a slight mechanical crimp of the lid  200  is formed to locate and hold the lid  200  on the bottle  12 . The crimp holds the lid  200  in place on the bottle  12  until the bottle  12  reaches a station  33  for sealing. Sealing may also be accomplished without having to provide the mechanical crimp on the lid  200 . 
     Another embodiment of a lid sterilization and heat sealing apparatus  552  is illustrated in FIG.  19 . As illustrated in FIG. 18, the daisy chain  215  of lids  200  includes a hole  207  located in each interconnecting band  203 . Each hole  207  receives a pin  209  of a drive sprocket  211 . 
     The daisy chain  215 A,  215 B of lids  200  is placed on each of a plurality of reels  210  (e.g.  210 A and  210 B). For the twelve bottle configuration of the present invention, six of the reels  210 , each holding a daisy chain  215 A,  215 B of lids  200 , are located on each side of a heat sealing apparatus  214 . Each daisy chain  215 A,  215 B of lids  200  winds off of a corresponding reel  210  and is sterilized preferably using a hydrogen peroxide bath  204 . The concentration of hydrogen peroxide can range from about 30 to 40%, however, preferably the concentration is about 35%. The lids  200  remain in the hydrogen peroxide bath  204  for at least about 6 seconds. A plurality of hot sterile air knives  208 , which are formed by jets of hot sterile air, activate the hydrogen peroxide to sterilize the lids  200  on the daisy chain  215 A,  215 B. The hot sterile air temperature is about 135° C. The hot air knives  208  also remove excess hydrogen peroxide form the lids  200 . A plurality of heated platens  205  further dry the lids  200  so that the residual concentration of hydrogen peroxide is less than 0.5 PPM. The hydrogen peroxide bath  204  prevents any contaminants from entering the sterilization tunnel  90  via the lidding operation. The drive sprocket  211 A includes a plurality of pins  209  that engage with the holes  207  of the daisy chain  215 A. The drive sprocket  211 A rotates in a counterclockwise direction and indexes and directs the daisy chain  215 A, through a plurality of guides  217 A. The guides  217 A may include a plurality of rollers  221 A to further guide and direct an end  219 A of the daisy chain  215 A over the bottle  12 A. The drive sprocket  211 B includes a plurality of pins  209  that engage with the holes  207  of the daisy chain  215 B. The drive sprocket  211 B rotates in a clockwise direction and indexes and directs the daisy chain  215 B through a plurality of guides  217 B. The guides  217 B may include a plurality of rollers  221 B to further guide and direct an end  219 B of the daisy chain  215 B over the bottle  12 B. 
     Once sterilized, the lids  200  enter the sterilization tunnel  90  where they are separated from the daisy chain  215 A,  217 B and placed on the bottle  12 A,  12 B. At station  33 , the lids  200  are applied to the bottles  12 . As illustrated in FIGS. 13 and 20, the heat sealing apparatus  214  includes a heated platen  216  that applies heat and pressure against each lid  200  for a predetermined length of time, to form a seal between the lid  200  and the bottle  12 A,  12 B. Although lidding for a bottle has been described, it should be appreciated that lidding of other containers (e.g. jars) can be provided by the present invention. FIG. 20 illustrates a perspective view of the heat sealing apparatus  214 , the daisy chain  215 A, the gripper apparatus  554 , the bottle  12 A, and the conveying plate  94 . The lid  200  is located above the bottle opening  16 . The gripper apparatus  554  includes a grip  223  for capturing the bottle  12 A by a bottle lip  225 . The gripper apparatus  554  lifts the bottle  12 A in an upward direction so that the lid  200  is pressed between a bottle top lip  227  and the heated platen  216 . The interconnecting band  203  severs and separates the lid  200  on the bottle  12  from the next lid on the daisy chain  215 A. The heated platen  216  is in a two by six configuration to seal twelve of the bottles  12  at a time. There is a separate gripper apparatus  554  for each of the twelve bottles  12 . After each bottle  12  is sealed, its gripper apparatus  554  lowers and releases the bottle  12  and each bottle  12  continues to station  37 . 
     At station  37 , the lid  200  seal and bottle  12  integrity are checked in a known manner by a seal integrity apparatus (not shown) comprising, for example, a bottle squeezing mechanism and a proximity sensor. Each bottle  12  is squeezed by the bottle squeezing mechanism which causes the lid  200  on the bottle  12  to extend upward. The proximity sensor detects if the lid  200  has extended upward, which indicates an acceptable seal, or whether the seal remains flat, which indicates a leaking seal or bottle  12 . The location of the defective bottles  12  are recorded by the control system  550  so that the defective bottles will not be packed. 
     Bottle discharge from the sterilization tunnel  90  of the filler apparatus  50  occurs at stations  38  and  40  as illustrated in FIGS. 3,  13  and  14 . A bottle discharge apparatus  280  is located at stations  38  and  40 . At this point in the filler apparatus  50 , the filled and sealed bottles  12  are forced in an upward direction such that a top portion  284  of each bottle  12  protrudes through the opening  282  in the sterilization tunnel  90  (FIG.  14 ). A rotating cam  290  or other suitable means (e.g., an inflatable diaphragm, etc.) may be used to apply a force against the bottom  120  of each bottle  12  to force the bottle  12  in an upward direction. 
     As illustrated in FIG. 14, the bottle discharge apparatus  280  comprises a lifting apparatus  286  that includes a gripper  288  that grasps the top portion  284  of each bottle  12  and lifts the bottle  12  out through the opening  282  in the sterilization tunnel  90 . In order to ensure that contaminated air cannot enter the sterilization tunnel  90 , the sterile air in the sterilization tunnel  90  is maintained at a higher pressure than the air outside the sterilization tunnel  90 . Thus, sterile air is always flowing out of the sterilization tunnel  90  through the opening  282 . In addition, the gripper  288  never enters the sterilization tunnel  90 , because the top portion  284  of the bottle  12  is first lifted out of the sterilization tunnel  90  by the action of the rotating cam  290  before being grabbed by the gripper  288 . 
     FIG. 15 illustrates a top view of the filler apparatus  50  including the bottle infeed and sterilization apparatus  60 , the interior bottle sterilization apparatus  116 , and the activation and drying apparatus  152 . FIG. 15 additionally illustrates the main filler apparatus  160 , the lid sterilization and heat sealing apparatus  162 , and the bottle discharge apparatus  280 . 
     Referring again to FIGS. 1 and 14, the lifting apparatus  286  lifts the bottles  12  at station  38  and places the bottles  12  in a first lane  292  that transports the bottles  12  to a first capping apparatus  410 . In addition, the lifting apparatus  286  lifts the bottles  12  at station  40  and places the bottles  12  in a second lane  294  that transports the bottles  12  to a second capping apparatus  400 . 
     The first capping apparatus  410  secures a cap (not shown) on the top of each bottle  12  in the first lane  292 . The second capping apparatus  400  secures a cap on the top of each bottle  12  in the second lane  294 . The caps are secured to the bottles  12  in a manner known in the art. It should be noted that the capping process may be performed outside of the sterilization tunnel  90  because each of the bottles  12  have previously been sealed within the sterilization tunnel  90  by the lid sterilization and heat sealing apparatus  162  using a sterile lid  200 . 
     After capping, the bottles  12  are transported via the first and second lanes  292 ,  294  to labelers  460  and  470 . The first labeling apparatus  470  applies a label to each bottle  12  in the first lane  292 . The second labeling apparatus  460  applies a label to each bottle  12  in the second lane  294 . 
     From the first labeling apparatus  470 , the bottles  12  are transported along a first set of multiple lanes (e.g.,  4 ) to a first case packing apparatus  490 . From the second labeling apparatus  460 , the bottles  12  are transported along a second set of multiple lanes to a second case packing apparatus  480 . Each case packing apparatus  480 ,  490  gathers and packs a plurality of the bottles  12  (e.g., twelve) in each case in a suitable (e.g., three by four) matrix. 
     A first conveyor  296  transports the cases output by the first case packer  490  to a first palletizer  510 . A second conveyor  298  transports the cases output by the second case packer  480  to a second palletizer  500 . A vehicle, such as a fork lift truck, then transports the pallets loaded with the cases of bottles  12  to a storage warehouse. 
     Referring again to FIG. 3, the main conveyor  106  and each conveying plate  94  are cleaned and sanitized once during each revolution of the main conveyor  106 . Specifically, after each empty conveying plate  94  passes around the pulley  108 , the conveying plate  94  is passed through a liquid sanitizing apparatus  300  and a drying apparatus  302 . The liquid sanitizing apparatus  300  sprays a mixture of a sterilizing agent (e.g., oxonia, (hydrogen peroxide and peroxyacetic acid)) over the entire surface of each conveying plate  94  and associated components of the main conveyor  106 . In the drying apparatus  302 , heated air with is used to dry the main conveyor  106  and conveying plates  94 . 
     Stations  1  through  40  are enclosed in the sterilization tunnel  90 . The sterilization tunnel  90  is supplied with air that is pressurized and sterilized. The interior of the sterilization tunnel  90  is maintained at a pressure higher than the outside environment in order to eliminate contamination during the bottle processing. In addition, to further ensure a sterile environment within the sterilization tunnel  90 , the sterile air supply provides a predetermined number of air changes (e.g., 2.5 changes of air per minute) in the sterilization tunnel  90 . 
     Before bottle production is initiated, the bottle infeed and sterilization apparatus  60  and the filler apparatus  50  are preferably sterilized with an aseptic sterilant. For example, a sterilant such as a hot hydrogen peroxide mist may be applied to all interior surfaces of the bottle infeed and sterilization apparatus  60  and the filler apparatus  50 . Then, hot sterile air is supplied to activate and remove the hydrogen peroxide, and to dry the interior surfaces of the bottle infeed and sterilization apparatus  60  and the filler apparatus  50 . 
     FIG. 16 is a side view of the aseptic processing apparatus  10  of the present invention indicating the location of the control and monitoring devices that are interfaced with the control system  550 . The control system  550  gathers information and controls process functions in the aseptic processing apparatus  10 . A preferred arrangement of the control and monitoring devices are indicated by encircled letters in FIG. 16. A functional description of each of the control and monitoring devices is listed below. It should be noted that these control and monitoring devices are only representative of the types of devices that may be used in the aseptic processing apparatus  10  of the present invention. Other types and combinations of control and monitoring devices may be used without departing from the intended scope of the present invention. Further, control system  550  may respond in different ways to the outputs of the control and monitoring devices. For example, the control system  550  may automatically adjust the operational parameters of the various components of the aseptic processing apparatus  10 , may generate and/or log error messages, or may even shut down the entire aseptic processing apparatus  10 . In the preferred embodiment of the present invention, the control and monitoring devices include: 
     A. A bottle counter to ensure that a predetermined number of the bottles  12  (e.g., six bottles) on each upper horizontal row  24 ,  28  enter the loading area of the bottle infeed and sterilization apparatus  60 . 
     B. A proximity sensor to ensure that the first group of bottles  12  has dropped into the first bottle position in the bottle infeed and sterilization apparatus  60 . 
     C1. A conductivity sensor to ensure that the measuring cup used by the sterilant application apparatus  36  is full. 
     C2. A conductivity sensor to ensure that the measuring cup used by the sterilant application apparatus  36  is emptied in a predetermined time. 
     C3. A pressure sensor to ensure that the pressure of the air used by the sterilant application apparatus  36  is within predetermined atomization requirements. 
     C4. A temperature sensor to ensure that each heat heating element used by the sterilant application apparatus  36  is heated to the correct temperature. 
     D. A proximity sensor (e.g., proximity sensor  71 , FIG. 3) to ensure that a bottle jam has not occurred within the bottle infeed and sterilization apparatus  60 . 
     E. A temperature sensor to ensure that the temperature of the heated sterile air entering the bottle infeed and sterilization apparatus  60  is correct. 
     F. A proximity sensor that to ensure that each conveying plate  94  is fully loaded with bottles  12 . 
     G1. A conductivity sensor to ensure that the measuring cup used by the interior bottle sterilization apparatus  116  is full. 
     G2. A conductivity sensor to ensure that the measuring cup used by the interior bottle sterilization apparatus  116  is emptied in a predetermined time. 
     G3. A pressure sensor to ensure that the pressure of the air used by the interior bottle sterilization apparatus  116  is within predetermined atomization requirements. 
     G4. A temperature sensor to ensure that each heat heating element used by the interior bottle sterilization apparatus  116  is heated to the correct temperature. 
     H. A temperature sensor to ensure that the air drying temperature within the activation and drying apparatus  152  is correct. 
     I. A plurality of flow sensors to ensure that the airflow rate of the sterile air entering the sterilization tunnel  90  is correct. 
     J. A pressure sensor to ensure that the pressure of the sterile air entering the activation and drying apparatus  152  is correct. 
     K. A measuring device (e.g., volumetric measuring device  188 , FIG. 3) to ensure that each bottle  12  is filled to a predetermined level. 
     L. A pressure sensor to ensure that the pressure in the product tank  182  is above a predetermined level. 
     M. A level sensor to ensure that the level of product in the product tank  182  is maintained at a predetermined level. 
     N. Proximity sensors to ensure that the daisy chains  202  of lids  200  are present in the lid sterilization and heat sealing apparatus  162   
     O. A level sensor to ensure that the hydrogen peroxide level in the hydrogen peroxide bath  204  in the lid sterilization and heat sealing apparatus  162  is above a predetermined level. 
     P. A temperature sensor to ensure that the temperature of the hot sterile air knives  208  of the lid sterilization and heat sealing apparatus  162  is correct. 
     Q. A temperature sensor to ensure that the heat sealing apparatus  214  is operating at the correct temperature. 
     R. Proximity sensors to ensure that the bottles  12  are discharged from the filler. 
     S. A speed sensor to measure the speed of the conveying apparatus  100 . 
     T. A concentration sensor to ensure that the concentration of oxonia is maintained at a predetermined level in the sanitizing apparatus  300 . 
     U. A pressure sensor to ensure that the pressure of the oxonia is maintained above a predetermined level in the sanitizing apparatus  300 . 
     V. A temperature sensor to ensure that the drying temperature of the drying apparatus  302  is correct. The following steps are performed during the “Clean In Place” (CIP) process in the filler apparatus  50 ; 
     23. Conductivity sensor to verify caustic and acid concentrations. 
     24. Temperature sensor to verify “Clean In Place” solution temperatures. 
     25. Flow meter to verify “Clean In Place” flow rates. 
     26. Time is monitored to ensure that adequate cleaning time is maintained. 
     The follow steps are performed during sterilization of the bottle filler apparatus  50 ; 
     27. Temperature sensors for measuring steam temperatures. 
     28. Proximity sensors to ensure filler nozzle cleaning/sterilization cups are in position. 
     29. Temperature sensors for air heating and cooling. 
     30. Flow meter for hydrogen peroxide injection. 
     31. Time is monitored to ensure the minimum time periods are met (steam, hydrogen peroxide application and activation/drying). 
     The foregoing description of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention.