Patent Description:
In an aseptic bottling line, there is the need to sterilize the containers formed before they are filled.

In this context, the attention is focused on chemical sterilization, in which the external and internal surfaces of the containers are treated with hydrogen peroxide, acetic acid or peracetic acid.

After the chemical treatment, the containers are rinsed with sterile water.

The main issue of chemical sterilization is connected with the disposal of chemical residues and the consumption of water for the rinsing step.

In accordance with a known solution, the rinsing water is purified by an active carbon filter, and it is then partially recycled in the process.

In another solution, the rinsing water is passed through a catalyst and then in an ion exchange resin.

From document <CIT> it is known a method for sterilizing and rinsing containers in aseptic applications.

From document <CIT> it is known an apparatus for sterilizing and rinsing containers which comprises a collector for recoverying the rinsing water at the rinsing carousel.

In this context, the object of the present invention is to provide an apparatus and a process for sterilizing and rinsing containers, which overcome the problems of the prior art cited above.

In particular, the object of the present invention is to propose an apparatus and a process for sterilizing and rinsing containers, which reduce the water consumption for the rinsing step.

Another object of the present invention is to propose an apparatus and a process for sterilizing and rinsing containers, having a lower environmental impact with respect to the known solutions.

The stated technical task and specified aims are substantially achieved by an apparatus and a process for sterilizing and rinsing containers as set out in the appended set of claims.

Further characteristics and advantages of the present invention will more fully emerge from the non-limiting description of a preferred but not exclusive embodiment of an apparatus and a process for sterilizing and rinsing containers, as illustrated in the accompanying drawings in which:.

With reference to the drawings, number <NUM> denotes an apparatus for sterilizing and rinsing containers <NUM>, in particular made of a thermoplastic material.

The apparatus <NUM> comprises a sterilizing unit <NUM> and a rinsing unit <NUM> arranged downstream the sterilizing unit <NUM>.

The sterilizing unit <NUM> is configured to treat the containers <NUM> by means of a sterilizing solution.

In particular, the apparatus <NUM> comprises a first tank <NUM> containing a sterilizing solution, which is a chemical compound based on one or more species of peroxides and/or organic acids.

In one example, the first tank <NUM> contains a peracetic acid solution.

The rinsing unit <NUM> is configured to rinse the containers <NUM> using sterile water.

In particular, the apparatus <NUM> comprises a UHT device <NUM> configured to provide sterile water, obtained by thermal treatment, to the rinsing unit <NUM>. Preferably, the apparatus <NUM> comprises a second tank <NUM> arranged downstream the UHT device <NUM> so as to receive the sterile water from it.

In practice, the sterile water obtained in the UHT device <NUM> is supplied to the second tank <NUM>.

In the rinsing unit <NUM> the containers <NUM> are made to advance along a path P.

The apparatus <NUM> further comprises dispensing means <NUM> in selective fluid communication with the UHT device <NUM>.

In one embodiment of the invention, illustrated in <FIG>, the second tank <NUM> is configured to receive the sterile water from the UHT device <NUM> and to supply it to the dispensing means <NUM>.

The dispensing means <NUM> are configured to dispense a first amount of sterile water towards the containers <NUM> in a first rinsing tract P1 of the path P and a second amount of sterile water towards the containers <NUM> in a second rinsing tract P2 of the path P.

In accordance with an embodiment of the invention, the dispensing means <NUM> are part of the rinsing unit <NUM>.

Preferably, the dispensing means <NUM> comprise a plurality of nozzles.

More preferably, the nozzles are external to the containers <NUM> and are configured to dispense sterile water on internal walls of the containers <NUM>. In an alternative embodiment, the nozzles are also configured to penetrate inside the containers <NUM> so as to dispense sterile water on internal walls of the containers <NUM>.

When the containers <NUM> move in the rinsing unit <NUM> they advance along the first rinsing tract P1 and then along the second rinsing tract P2.

The second rinsing tract P2 is downstream the first rinsing tract P1 with respect to the advancement direction of the containers <NUM> along the path P in the rinsing unit <NUM>.

In one example, the second rinsing tract P2 is immediately consecutive to the first rinsing tract P1. In another example, the second rinsing tract P2 is successive to the first rinsing tract P1 but separated from that.

Preferably, the dispensing means <NUM> are configured to dispense sterile water by a single dispensing pulse which supplies both the first amount of sterile water and the second amount of sterile water.

Alternatively, the dispensing means <NUM> are configured to dispense the first amount of sterile water with a first dispensing pulse, and the second amount of sterile water with a second dispensing pulse. In practice, the second dispensing pulse occurs after the first dispensing pulse has finished.

Advantageously, the apparatus <NUM> further comprises a recovery collector <NUM> arranged in the rinsing unit <NUM>, in particular at the second rinsing tract P2 for collecting at least one part of the exhaust sterile water dropping from the containers <NUM> advancing along the second rinsing tract P2.

The recovery collector <NUM> is in selective fluid communication with the second tank <NUM> via the UHT device <NUM> so as to recover the collected exhaust sterile water dropping from the containers <NUM> in the second rinsing tract P2.

The apparatus <NUM> comprises a further recovery collector <NUM> arranged in the rinsing unit <NUM>, in particular at the first rinsing tract P1 for collecting at least part of the exhaust sterile water dropping from the containers <NUM> advancing along the first rinsing tract P1.

The further recovery collector <NUM> is in selective fluid communication with the first tank <NUM> so as to recover the collected exhaust sterile water dropping from the containers <NUM> in the first rinsing tract P1.

In particular, the recovery collector <NUM> and the further recovery collector <NUM> are separated, i.e. they are not in fluid communication. As a matter of fact, they are configured to collect exhaust sterile water in two different zones of the rinsing unit <NUM>, which correspond to different contents of peroxides.

Preferably, the apparatus <NUM> comprises a piping system <NUM> configured to establish a selective fluid communication between the recovery collector <NUM> and the UHT device <NUM>, which in turn feeds the second tank <NUM>. In particular, the piping system <NUM> is configured to channelize the exhaust sterile water recovered from the recovery collector <NUM> towards the UHT device <NUM>.

For example, the piping system <NUM> comprises a pump.

Analogously, the apparatus <NUM> comprises a further piping system <NUM> configured to establish a selective fluid communication between the further recovery collector <NUM> and the first tank <NUM>. In particular, the further piping system <NUM> is configured to channelize the exhaust sterile water recovered from the further recovery collector <NUM> towards the first tank <NUM>.

For example, the further piping system <NUM> comprises another pump.

Preferably, the recovery collector <NUM> and the further recovery collector <NUM> are each designed as leak pans configured to collect dropping water.

Said leak pans are respectively arranged below the first rinsing tract P1 and the second rinsing tract P2, as shown in <FIG>.

According to one embodiment of the invention, illustrated in <FIG>, the apparatus <NUM> is of the rotating type. Therefore, both the sterilizing unit <NUM> and the rinsing unit <NUM> comprise a rotating carousel.

In this embodiment, the path P along the rinsing unit <NUM> is a curvilinear path. The first rinsing tract P1 and the second rinsing tract P2 are arcuate portions of the curvilinear path P.

According to another embodiment of the invention (not illustrated), the apparatus <NUM> is of the linear type. Therefore, both the sterilizing unit <NUM> and the rinsing unit <NUM> comprise a linear conveyor or belt.

In this embodiment, the path P along the rinsing unit <NUM> is a linear path.

The first rinsing tract P1 and the second rinsing tract P2 are linear portions of the linear path P.

The process for sterilizing and rinsing containers, according to the present invention, is described hereafter.

The containers <NUM> are first sterilized with a sterilizing solution.

In the embodiment described and illustrated herewith, the containers <NUM> are sterilized in the sterilizing unit <NUM> by the sterilizing solution coming from the first tank <NUM>.

After having been sterilized, the containers <NUM> are rinsed. According to one aspect of the invention, the containers <NUM> undergo two rinsing steps.

In particular, both the rinsing steps occur in the rinsing unit <NUM>.

In a first rinsing tract P1 of the path P of the containers <NUM> in the rinsing unit <NUM>, the containers <NUM> undergo a first rinsing step. For the first rinsing step it is employed a first amount of sterile water coming from the second tank <NUM>.

The first amount of sterile water is dispensed towards the containers <NUM> when they are moving along the first rinsing tract P1.

In particular, the first amount of sterile water is dispensed by nozzles (not illustrated) which are in selective fluid communication with the UHT device <NUM> (and in particular with the second tank <NUM>).

At least a part of exhaust sterile water used during the first rinsing step is recovered for being used for sterilizing new containers <NUM>.

In particular, part of the exhaust sterile water dropping from the containers <NUM> which undergo the first rinsing step is collected by the further recovery collector <NUM> and sent back to the first tank <NUM>.

This part of exhaust sterile water recovered from the first rinsing step is called here "first recovered water".

After the first rinsing step, the first recovered water was monitored and analyzed. The content of peroxides within the first recovered water is in the range of <NUM>-<NUM> ppm.

It was noticed that the concentration of peroxides in the first recovered water was compatible for being mixed with the sterilizing solution of the first tank <NUM> without affecting it.

Thus, the first recovered water is used for sterilizing new containers <NUM> in the sterilizing unit <NUM>.

After the first rinsing step, the process comprises a second rinsing step which is carried out in a second rinsing tract P2 of the path P.

For the second rinsing step it is employed a second amount of sterile water coming from the second tank <NUM>.

The second amount of sterile water is dispensed towards the containers <NUM> when they are moving along the second rinsing tract P2.

In particular, the second amount of sterile water is dispensed by nozzles (not illustrated) which are in selective fluid communication with the UHT device <NUM> (and therefore with the second tank <NUM>).

In one embodiment of the process, the dispensing means <NUM> (i.e. the nozzles) are configured to dispense the sterile water by a single dispensing pulse (without any interruption) that spans both the first rinsing step and the second rinsing step. In other words, there is no interruption between dispensing the first amount of sterile water and the second amount of sterile water.

In another embodiment of the process, the dispensing means <NUM> are configured to dispense the first amount of sterile water with a first dispensing pulse, and the second amount of sterile water with a second dispensing pulse. In practice, the second dispensing pulse occurs after the first dispensing pulse has finished.

At least a part of exhaust sterile water used during the second rinsing step is recovered for being used in rinsing new containers <NUM>.

In particular, part of the exhaust sterile water dropping from the containers <NUM> which undergo the second rinsing step is collected by the recovery collector <NUM> and sent back to the UHT device <NUM>.

This part of exhaust sterile water recovered from the second rinsing step is called here "second recovered water".

After the second rinsing step, the second recovered water was monitored and analyzed. The content of peroxides within the second recovered water is in the range of <NUM>-<NUM> ppm.

This concentration of peroxides is lower than the concentration of peroxides in the first recovered water. This is due to the fact that containers <NUM> undergoing the second rinsing have already been rinsed in the first rinsing step, thus they have lower peroxide residues.

In particular, it was noticed that the concentration of peroxides in the second recovered water was sufficiently low for being compatible with the UHT device <NUM> for generating sterile water.

Thus, the second recovered water is used for rinsing new containers <NUM> in the rinsing unit <NUM>, in particular in the first rinsing tract P1 and/or in the second rinsing tract P2.

As said, only part of the exhaust sterile water used to rinse the containers <NUM> is recovered and may be used in the next rinsing cycles.

There is a part of exhaust sterile water which drops from the containers <NUM> and is neither collected by the recovery collector <NUM> nor by the further recovery collector <NUM>. This part of exhaust sterile water may be discharged by means of a discharge outlet or may be channelized and reused in another way within the apparatus <NUM>.

The characteristics of the apparatus and process for sterilizing and rinsing containers, according to the present invention, are clear, as are the advantages.

In particular, the invention allows a partial recovery of the exhaust sterile water used for rinsing the containers. Depending on the content of peroxides the recovered exhaust sterile water may be used for sterilizing or for rinsing new containers.

In particular, after the second rinsing step the content of peroxides is sufficiently lower for allowing the recovered exhaust sterile water to be used for next rinsing after having been thermally treated. There is no need to further treat or filter this recovered water since the content of peroxides is sufficiently low to be submitted as is to the UHT device.

The recovery of part of the sterile water for next rinsing steps is even more advantageous since the consumption of fresh water to produce sterile water is reduced.

Claim 1:
An apparatus (<NUM>) for sterilizing and rinsing containers (<NUM>), comprising:
- a sterilizing unit (<NUM>) configured to treat the containers (<NUM>) by means of a sterilizing solution contained in a first tank (<NUM>), said sterilizing unit (<NUM>) comprising a corresponding rotating carousel;
- a rinsing unit (<NUM>) arranged downstream the sterilizing unit (<NUM>) and configured to rinse the containers (<NUM>) advancing along a path (P) with sterile water, said rinsing unit (<NUM>) comprising a corresponding rotating carousel, said path (P) along the rinsing unit (<NUM>) being a curvilinear path;
- a UHT device (<NUM>) configured to provide sterile water to the rinsing unit (<NUM>);
- dispensing means (<NUM>) in selective fluid communication with the UHT device (<NUM>) so as to dispense a first amount of sterile water towards the containers (<NUM>) in a first rinsing tract (P1) of the path (P) and a second amount of sterile water towards the containers (<NUM>) in a second rinsing tract (P2) of the path (P) that is downstream the first rinsing tract (P1), the first rinsing tract (P1) and the second rinsing tract (P2) being arcuate portions of the curvilinear path (P);
- a recovery collector (<NUM>) arranged at the second rinsing tract (P2) of the path (P) for collecting at least part of exhaust sterile water dropping from the containers (<NUM>) advancing along the second rinsing tract (P2), said recovery collector (<NUM>) being in selective fluid communication with the UHT device (<NUM>);
- a further recovery collector (<NUM>) arranged at the first rinsing tract (P1) of the path (P) for collecting at least part of the exhaust sterile water dropping from the containers (<NUM>) advancing along the first rinsing tract (P1), said further recovery collector (<NUM>) being in selective fluid communication with the first tank (<NUM>), said recovery collector (<NUM>) and the further recovery collector (<NUM>) being separated, that means not in fluid communication.