Patent Publication Number: US-2015059292-A1

Title: Method and device for filling large containers

Description:
The present invention relates to a method and a device for filling containers, in particular plastic containers and in particular large plastic containers. Such large plastic containers are known from the prior art. These can be used for example in tapping systems for drawing off large quantities of drinks. Various methods and devices for filling such large containers are known from the prior art. In particular, because of the relatively high volume of these containers and the filling weight, the transport of such containers often constitutes a problem. 
     Therefore a method and a device are proposed which, in particular when applied to large containers, allow simplified and economic production. This is achieved according to the invention by a method and a device according to the independent claims. Advantageous embodiments and refinements are the subject of the subclaims. 
     In a method according to the invention for producing drinks containers, first a compressed container is provided. This compressed container is then exposed to a gaseous medium in order to be expanded, wherein preferably during expansion a wall thickness of the container does not change by more than 10%. Finally this expanded container is filled with a fluid. 
     It is pointed out that the process of expansion with gaseous medium is not a blow-moulding process in which, as known from the prior art, plastic preforms are expanded into plastic containers, but this is a process in which a container already produced but compressed is expanded and in particular unfolded. 
     In the internal prior art of the applicant, a method is known in which this expansion of the compressed container takes place using the actual fluid to be filled. 
     By deviation from this it is now proposed that first the container is filled with a gas for expansion and then only later filled with a fluid. 
     In addition it is also still possible to fit a carrier element to the container and/or a label. 
     Preferably the drinks containers are plastic containers, but an application to other materials such as in particular aluminium barrels would be conceivable. 
     Preferably the container is unfolded by exposure to a gaseous medium. It would be possible for the container to be compressed by a folding process in a preceding step, and then as described here unfolded by exposure to the gaseous medium. 
     In a preferred method, the container is unfolded along a preferably peripheral folding edge. Advantageously, in a compressed state the container has only one such peripheral folding edge. 
     In a further advantageous method, a cross-section of at least one portion of the container remains unchanged during expansion. This can for example be a cross-section in the region of the container floor into which another region of the container is folded, for example a mouth region of the container. 
     In a further advantageous method, the container is compressed by a compression process before expansion. 
     In contrast to methods from the prior art, it is proposed here that first a plastic container is produced, in particular by a blowing process, and then this container is compressed again. Only in a further method step is the container expanded again, in particular by exposure to a gaseous medium. In this way it can be achieved that a filling plant can function without corresponding blow-moulding machines. In other words, the container is first brought into a produced but compressed form at a manufacturer&#39;s plant, and then expanded by the expansion process (in a filling plant). In this case the filling plant requires only devices such as for example filling machines and an expansion device to expand the container. 
     It would also be possible to use the containers multiple times. In this case the step of producing the container can be omitted and replaced by provision of the container. Such a container could be compressed and then unfolded again several times. 
     In a preferred method, the container is rolled up for compression so that a mouth region of the container lies inside another region of the container. Here the container can be crushed in its longitudinal direction using dies such that a specific region of the container, in particular an upper region, is pushed or rolled into the lower region. Advantageously such compression or rolling of the plastic pre-container takes place along a preferably peripheral folding edge. 
     In a further preferred method, the container is compressed or rolled together such that it can be stacked with further compressed or rolled containers produced in the same way. Preferably however a container is produced here which can be stacked as a whole with a plurality of similar containers. 
     Another foldable container is described in the as yet unpublished DE 10 2012 101 868.5, the disclosure of which—in particular on pages 7 to 9—fully forms part of the disclosure content of the present application by reference. 
     Such a container—in particular a plastic container—which can be filled with a fluid has a mouth, a floor region and a base body formed integrally with the mouth and floor region. In folded state of the container, the base body is bent through a predefined bending angle about a predefined peripheral folding edge of the base body such that the mouth of the container is arranged closer to the floor region than the peripheral folding edge. According to the invention, a relative position (and/or distance) of the folding edge in relation to the floor region of the container can be changed during expansion of the container. Advantageously a relative position of the folding edge in relation to the mouth of the container can be changed during expansion of the container. 
     Thus a foldable container is proposed which in particular is folded such that the mouth region lies close to the floor region of the container. Thus advantageously the base body itself is folded up with at least one folding edge and preferably precisely one folding edge. Advantageously the container is a plastic container. In addition however another foldable material can be used. 
     In a preferred embodiment, an outer surface of the base body lies peripherally, at least in portions, opposite an inner surface of the base body, in particular in a radial direction of the container. In this way in folded state of the container, a very effective inner volume reduction is achieved. 
     Preferably the outer surfaces and inner surfaces of the container, at least in portions, have a distance apart which is &lt;0.2 cm. Advantageously this is a peripheral distance and particularly preferably a distance in a radial direction of the container. 
     In a further advantageous embodiment, a wall thickness of the base body is substantially constant at least in portions (and particularly preferably in the entire region of the base body). It is thus proposed here that it is not a thin-walled region which is laid on another region for folding of the container, but preferably a wall region with substantially constant wall thickness is folded. Said folding edge advantageously is moveable during the expansion process. It is therefore not a constant folding edge proposed about which the folding process is performed, but a moveable folding region which also migrates during expansion of the container. 
     Finally from the as yet unpublished prior art of the applicant, namely the above-mentioned DE 10 2012 101 868.5, an apparatus and a method are also known by means of which a container is filled with a fluid and can also be expanded. The subject of this disclosure, in particular the description of the individual method steps and the associated container on pages 2 to 5, is also made the subject of the present application by reference. 
     In a method for filling a container with a fluid, the container is filled via a mouth of the container and an inner volume of the container expands during the filling. The inner volume of the subsequently filled container is at least double (preferably at least three times, preferably at least five times and particularly preferably at least ten times) the volume of the unfilled container. 
     It is therefore proposed that the container is expanded before the filling process, here by exposure to the gaseous medium. The container is thus inflated immediately before the filling process. 
     Advantageously therefore, during this expansion process no stretching—or at least no significant stretching—of the wall and/or material of the plastic container takes place, but in particular merely an unfolding. Preferably therefore the container to be filled, as well as its mouth, already has its definitive form in at least one region of the container, preferably in a floor region. 
     Thus it is possible in particular that the container produced by the expansion process is folded such that its inner volume is reduced. In folded state, preferably a predefined wall portion and in particular a peripheral wall portion lies next to a further predefined wall portion, and in particular a further peripheral wall portion. Advantageously, in folded state of the container these wall portions touch at least in portions and preferably along a peripheral surface. 
     In a further advantageous method, the container is folded or rolled up such that the volume ratio between the plastic preform and volume-reduced container is less than 1:2, preferably 1:1.5, and particularly preferably less than 1:1. Advantageously a volume ratio between the plastic preform and the unrolled container is 1:50 in the case of a 20-litre container. 
     Preferably on said crushing or folding process, a crushing of the material also takes place which is preferably permanent. Preferably this deformation is also present after filling under pressure. 
     Advantageously the container is formed in cold state and in particular without the action of heat. This can mean that for example after forming into plastic containers, the plastic preforms are cooled before they are compressed or folded. It may however also suffice not to heat the plastic containers further. 
     In a further preferred method, a container closure is applied to the container after production. In contrast to the method known from the prior art, the closure is applied before the container is filled with a fluid. Here it is possible that the closure is applied to the container before it is compressed, but it would however also be possible for the closure to be applied to the container after it has been compressed. 
     It would be possible for a valve closure to be arranged before or after compression, but the possibility exists of applying the closure only after the filling process. In this case a valve closure could be used but also a standard screw closure which is then preferably punctured on drainage of the container. 
     Thus for example for closing, a valve closure can be used which allows the escape of air during compression. This is preferably a valve closure through which filling can take place and particularly preferably a valve closure through which drainage can also take place. 
     Here it is possible that this closure is applied immediately after the blowing process. Also a screw closure can be used which is preferably applied only after the filling process. 
     In a further method step it would be conceivable for the container to be filled through this closure. Advantageously this closure can have a valve device which allows filling and draining of the container. For draining the container, preferably a region of the container and in particular said closure can be punctured. 
     In a further advantageous method, a container closure is applied to the container before it is compressed. This process offers the advantage of making it easier to apply the closure to the produced but as yet uncompressed container, since in this case the mouth is more easily accessible than in a compressed container. Advantageously in this case a closure is used which allows a gas escape, in particular for the purpose of compression of the container. 
     In a further preferred method, a plurality of plastic containers is produced and these plastic containers are compiled in a compressed state into a container assembly. Preferably these containers are stacked in each other. The compressed containers can be stacked on their heads, i.e. inverted so that the opening is at the bottom. In a further preferred method, these container assemblies can also be palletised. Preferably the containers are assembled for transport purposes. It is possible that the container assemblies are transported from a production site to a usage site. The containers could be produced by a production company and also palletised or assembled, then transported to a filler and here filled with a drink. The advantage of this procedure is that the containers can be transported in very compact state. 
     In a further preferred method, after production of the container, a carrier element is arranged thereon. This can for example be a carrying handle. As stated above, the containers concerned are very large or have a high weight in filled state. Therefore it is preferred to arrange a carrier element, such as in particular a carrying handle, on these containers. It is possible to arrange this carrier element on the container immediately after its production. It would however also be conceivable for the carrier element to be arranged on the container during its formation or blow-moulding. Advantageously the carrier element is arranged on a mouth portion of the container. 
     Furthermore it would however also be conceivable for the carrier element to be arranged on a container which is in a folded state. Furthermore it is also possible for the carrier element to be arranged on the container before or after its closure. Advantageously the carrier element can be placed or pushed onto a mouth of the container. 
     The as yet unpublished patent application no. 10 2013 102 748 also describes such a carrier element and a method for attaching this to the container. The subject of this disclosure, in particular pages 4 to 10, is hereby made the subject of the present application in full by reference. 
     The carrier element may be used for carrying moveable bodies. The carrier element is advantageously, at least in portions, designed flexibly and has a fixing portion with which, for at least part of the time, it can be attached to a body and in particular to the container. This fixing portion preferably has an opening through which at least one portion of the container can be guided, and at least one first handle portion connected to the fixing portion and having an opening through which a region of a human hand can be guided. This opening is preferably delimited by several edge regions, wherein a holding element, flexible in relation to an edge region, is arranged on at least this one edge region and extends in the direction of the opening. 
     Advantageously the carrier element is formed integrally, and particularly preferably made from plastic. Advantageously at least one region of the carrier element is flexible so it can be bent through an angle of more than 30°, preferably more than 60°. Furthermore also preferably the holding element can be bent in relation to the edge region on which it is arranged, and preferably as stated above through an angle of at least 30°, preferably at least 60°, preferably at least 90°, preferably at least 120°. 
     Advantageously the several edge regions form a closed periphery. Advantageously these are edge regions running rectilinearly at least in portions. Advantageously the opening has a rectangular cross-section. 
     In a further advantageous embodiment, the carrier element has a material thickness in the region of the handle portion which is between 1 mm and 10 mm, preferably between 2 mm and 4 mm. 
     In a further advantageous embodiment, a plurality of protrusions is arranged on the fixing portion, which point to the body when fixed on this body. 
     Advantageously the carrier element is detachable from the container which it has to carry. In this way the carrier element can be arranged on the body solely for the purpose of carrying and then detached from this again. 
     Preferably the carrier element is flexible such that on folding of the container on which it is arranged, it adapts to the deformations of the container at least in portions. Thus for example on folding of the container, the carrier element can lie at a mouth region of the container. In this way it is also possible for several folded containers to be placed inside each other, in particular for transport purposes, wherein the carrier element can also be attached to the individual containers in this state. 
     In a further advantageous embodiment, the container assembly is transported to a filling device. In particular the container assembly can be transported from a production plant to a filling plant. 
     In a further advantageous method, the container is labelled after compression. Here it is possible for the container to be labelled in compressed state, but it would however also be possible for the container to be labelled before it is assembled with a plurality of further containers into a container assembly. It would however also be conceivable for the container to be labelled only after transport, for example in a filler plant. In this way the variability is increased for the filling plant. Preferably however the container is labelled before filling. 
     In this embodiment preferably the label is arranged on a lower part region of the container. Instead of labelling it would however also be possible for the container to be printed, or for markings to be burned on or similar, in particular by means of a laser. Also other markings can be applied to the container which for example are characteristic of a filling date, a production date, an expiry date or similar. 
     In a further preferred method, a plastic preform is produced and from this plastic preform the plastic container is produced by a blowing process. Advantageously the plastic preform is produced by a stretch-blowing process. It is preferably possible for the plastic container to be produced directly after production of the plastic preform. 
     Advantageously for this a machine or device is used which is arranged immediately upstream of the forming device for forming the plastic preforms into plastic containers. 
     Preferably therefore the container is compressed by a compression process before expansion. 
     In a further advantageous method, as stated above the container is produced by a blow-moulding process. Thus the container is first produced by a blow-moulding process, then compressed and finally expanded again. 
     In a further advantageous method, the compressed container is expanded by means of a gas selected from a group of gases containing nitrogen and carbon dioxide. 
     Thus in particular it is proposed here that the containers are unfolded or unrolled not during filling but before, in particular by means of CO 2  or optionally nitrogen (N 2 ). In the case of a phased machine, this can take place immediately before the latter. In this case the open containers or vessels could be delivered directly to the next working step. In this case the containers are then filled completely (100%) with CO 2  and need then only be flushed minimally or not at all. In large plants this can take place semi-automatically, for example in a dry part, from which the containers (optionally closed) can be transported to a filling device for example via air transport or a transport device such as a conveyor belt or conveyor chain. 
     There a closure can be removed and the container filled. In addition it is also conceivable for a closure to be reused after removal. A container could be inflated before filling with CO 2  and preferably also pre-tensioned, which can take place in particular directly in a filling station. 
     Before inflation however, in the embodiments described here the rolled container can also be exposed to a vacuum. 
     In other words, the container is evacuated preferably before exposure to the gaseous medium. This can take place for the purpose of fully removing air from the container, in order in this way to increase the conservability of a drink which is filled later. 
     Preferably before exposure to the gaseous medium, a closing element for closing the container is removed from the container mouth. Thus it is conceivable that first the container is formed and then compressed, and in this compressed state a closure is applied to the compressed container. Also it would be possible for a closure to be applied to the container before it is compressed. 
     The advantage of the embodiment described here, in particular for small filling plants or breweries, is that the process of unrolling with CO 2  can take place in a dry environment before the actual filling station. Thus filling can take place in a clean environment. Also for a high-power filler for large vessels, the filler and the container handling are simplified in that the complex mechanism required for unrolling is located upstream. The advantage of reducing the CO 2  consumption is retained since the container is not flushed but merely inflated once with CO 2 . 
     The present invention is furthermore directed at an apparatus for producing containers filled with fluids. This apparatus has an expansion device which is suitable and intended for expanding containers, already produced by a forming process and then compressed, by exposure to a gaseous medium. Furthermore a filling device is provided downstream of the expansion device in a transport direction of the containers, which fills the expanded containers with a fluid. Advantageously therefore a transport device is also provided which transports the containers through the expansion device during expansion. 
     Preferably a transport device is also provided which transports the containers from the expansion device to a filling device. 
     In a further advantageous embodiment it is also conceivable that gas expelled again from the container during the filling process, for example CO 2 , can be reused for expansion of a further container. Thus for example a reservoir for the gaseous medium can be provided from which the containers are expanded. 
     In a further advantageous embodiment, a complete plant also has a container production apparatus which is in particular a blow-moulding machine. Advantageously a compression device is also provided which for example compresses the containers produced by the blow-moulding process. In addition a container assembly device can be provided which compiles a plurality of compressed containers into a group, for example stacking them in each other. 
    
    
     
       Further advantages and embodiments arise from the enclosed drawing which shows: 
         FIG. 1  a diagrammatic sequence of a method according to the invention and an apparatus according to the invention; and 
         FIG. 2  a further depiction of a pallet with containers. 
     
    
    
       FIG. 1  shows a typical sequence of a method according to the invention. It is however pointed out that individual method steps may also be carried out in a different order, and furthermore that individual method steps such as arranging a handle on the container are optional. 
     As part of the method according to the invention, first plastic preforms  5  are produced with a preform production device  22 . The arrows below the individual elements illustrate the process sequence. For example this plastic preform  5  can be produced in a company, e.g. a converter. In a further method step the plastic preform  5  is inflated into a plastic container  10 , wherein a forming apparatus  2  is used for this. This forming apparatus  2  is in particular but not exclusively a blow-moulding machine, such as a stretch-blowing machine. 
     In a further method step, a closure  44  is arranged on the container, for example screwed on. This is in particular a closure having a valve. To this end a closing device  3  is provided which fits the closure to the container, for example screwing it to the container (could also be pressed on). 
     In a further method step, a carrier element  42 , for example a carrying handle, is arranged on the container. This can then for example be pushed over the existing closure. Reference numeral  24  designates an apparatus which can for example attach the carrying handle to the container. 
     In a further method step, the container is compressed under control and in particular rolled up. Reference numeral  4  designates the corresponding apparatus for achieving this rolling or compression process. In contrast to methods known from the prior art, an empty container is thus here compressed under control. 
     In a further method step, a container assembly  50  is formed from a plurality of compressed containers. For this an assembly-forming device  6  is provided. Furthermore the container assemblies thus formed are palletised, wherein for example a pallet can contain 500 to 560 containers (the capacity can in fact be higher but restrictions may result due to the 40′ container/semitrailer height). To this end, a palletiser  8  can be provided. Containers can be palletised with their feet downwards, but also with their feet upwards i.e. lying on a fold ring. The containers need not however stand on a pallet, they can also be packed and dispatched in a box with cover and film inside etc. 
     Then the palletised containers are transported by means of a transport means  15 , here shown as a truck, to a further company for example a filling plant. 
     At the filling plant first the pallets  52  are depalletised, whereby a depalletising apparatus  26  is provided (can also be done manually). In addition the container assemblies formed in this way can be separated, more precisely the containers from these container assemblies can be separated, which can take place via a separation device  27  (can also be done manually). It would also be possible here for the closure to be removed from the containers in the following step. 
     In a further method step, the containers are expanded or unfolded, wherein an expansion device  36  is used. This preferably exposes the containers to a gas such as in particular carbon dioxide or nitrogen. 
     In a further method step, the containers are labelled using a labelling apparatus  28 . Here for example the containers as stated above can be labelled in a lower half region of the containers, i.e. in a half region close to the floor. Since however at this time the containers have already been re-expanded, in principle their entire outer surface can be used for labelling. 
     In addition however there is the possibility of labelling only after filling, and applying a sleeve label. 
     In a further method step the containers are filled. Reference numeral  12  designates a corresponding filling device. In a further method step it would still be possible to remove gas or oxygen from the head space of the containers in that, for example by means of a pressurization device, other gases such as nitrogen could be supplied after filling. In this way the conservability of the filled product inside the container can be extended. 
     The filled containers are closed by means of a closing device  14 . 
     By means of a further apparatus, a second closing device, for example a hygiene or safety cover, can (but need not) be applied to the container or closure  44  of the container. Alternatively, the application of a blister packing is conceivable, containing a single-use drink line. This blister packing seals the opening of the closure and can also serve as a hygiene or safety cover. 
     With a further palletising device  32 , the now filled containers are re-palletised onto a pallet  56  (i.e. strapped or film-wrapped) and finally by means of a further transport device  34  (here again a truck), they can brought to the individual customers. 
     It would however also be possible for the method depicted here to be carried out with re-usable containers, i.e. for example the above-mentioned step of production of the plastic container, for example by a blow-moulding process, does not take place but an existing container is rolled up a second time. 
       FIG. 2  shows a further embodiment of a pallet with containers  10 . Here in addition to the carrier element a receiver element  18  or receiver device is arranged on the containers  10 . This receiver element  18  forms a receiving chamber (not shown) in which further elements such as a (single use) tapping line and similar can be accommodated. The receiver element can have an opening via which a closure of the container  10  can be pushed or pressed on. 
     The applicant reserves the right to claim as essential to the invention all features disclosed in the application documents where novel individually or in combination in relation to the prior art. 
     LIST OF REFERENCE NUMERALS 
       2  Forming apparatus 
       3  Closing device 
       4  Compression apparatus 
       5  Plastic preform 
       6  Assembly-forming device 
       8  Palletiser 
       10  Plastic container 
       12  Filling device 
       14  Closing device 
       15  Transport means 
       18  Receiver element 
       22  Preform production device 
       24  Device for application of a carrying handle 
       26  Depalletising apparatus 
       27  Separation device 
       28  Labelling apparatus 
       32  Palletising device 
       34  Transport device 
       36  Expansion device for expanding the compressed containers 
       42  Carrier element 
       44  Closure 
       50  Container assembly 
       52  Pallets 
       56  Pallet 
       58  Carrier