Patent Application
20160194189
The present invention relates to a machine and a method for filling containers with pourable products, in particular carbonated liquids, such as sparkling water, soft drinks and beer, which the following description will refer to, although this is in no way intended to limit the scope of protection as defined by the accompanying claims.
The present invention may be also used to particular advantage for any type of container, such as containers or bottles made of glass, plastics, aluminum, steel and composites, and for any type of pourable product, such as non-carbonated liquids (including still water, juices, teas, sport drinks, liquid cleaners, wine, etc), emulsions, suspensions and high viscosity liquids.
As is known, many pourable products are sold in a wide range of bottles or containers, which are sterilized, filled and closed in container handling plants typically including a plurality of processing stations or machines, such as rinsing machines, filling machines, capping machines and labelling machines.
These processing stations can be defined by linear machines or, more frequently, by carousel-type machines. The following description will refer to carousel-type machines only, although this is in no way intended to limit the scope of protection of the present application.
The containers to be handled are generally fed to and removed from these machines by means of a transport system including star wheels and linear conveyors.
Known container handling plants are therefore fairly bulky and allow little freedom of choice in terms of layout; moreover, this kind of plants requires quite complicated adjustments to synchronize the different processing stations and entails relatively high operating and maintenance costs.
Another problem posed in respect of known filling machines is the formation of foam at the end of the operation of filling the container.
This problem is mainly caused by the fact that, for reasons of economy, commercial containers are not such larger than the volume required for accommodating of the contents. Thus, during filling operations, which have to be carried out at high speed, it is common for some amount of liquid in the form of foam to bubble over the top of the container prior to the container being capped or sealed. The product loss can be as high as ten percent, which translates into higher cost for the consumer or lower profitability for the bottler, or both.
To reduce this product loss, some filling machines include a dwell station that allows for the product foam in a recently filled container to settle prior to capping.
Other filling machines include a short suction pipe adapted to be introduced into the container to be sealed, and a suction system whereby the foam over the top surface of the liquid is removed and optionally recycled into the product reservoir.
Some filling machines may also use blast nozzles for blowing any drops and residual foam from the surfaces to be sealed or capped.
Some filling machines reduce the temperature of the liquid at the mixing tanks or other reservoirs to reduce foaming.
In certain cases, the containers are purposefully overfilled to compensate for lost product in the form of foam and thereby achieve the desired net fill volume, which results in undesirable product loss.
Other possible solutions are based on the use of ultrasonic waves for collapsing the foam; in practice, the portion of liquid forming the foam again becomes part of the liquid content of the container rather than being wasted.
It is an object of the present invention to provide a machine for filling containers, designed to eliminate at least one of the aforementioned drawbacks, and which is cheap and easy to implement.
According to one aspect of the present invention, there is provided a machine for filling containers as claimed in claim 1.
The present invention also relates to a method for filling containers as claimed in claim 15.
According to another aspect of the present invention, there is provided a machine for filling containers as claimed in claim 23.
The present invention also relates to a method for filling containers as claimed in claim 30.
A non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:
Number 1 in
As visible in
In the example shown, the bottles 2 filled by machine 1 are made of plastics; however, machine 1 may be also used for other types of containers, such as containers made of aluminum, steel, glass and composites. Moreover, the containers used in machine 1 may be filled with any type of pourable product, including non-carbonated liquids (such as still water, juices, teas, sport drinks, liquid cleaners, wine, etc), emulsions, suspensions and high viscosity liquids.
Machine 1 comprises a conveying device 5 that, according to the present invention, serves not only to fill the bottles 2 but also to label them during the filling process.
In the preferred embodiment as illustrated on the figures, the conveying device 5 comprises a carousel 6, which is mounted to rotate continuously (anticlockwise in
Machine 1 further comprises a plurality of handling units 12, which are equally spaced angularly about axis B, are mounted along a peripheral portion 11 of carousel 6, and are moved by the carousel 6 along a path P extending about axis B and through stations 8 and 10.
As shown in the enclosed Figures, each handling unit 12 comprises a support device 13 adapted to receive and retain a relative bottle 2 in a vertical position, in which such bottle 2 has its axis A parallel to the axis B of carousel 6, and a filling device 14 for feeding the pourable product into a bottle 2 as the support device 13 travels along path P.
Each filling device 14 is conveniently arranged above the bottle 2 to be filled.
With particular reference to
Support plate 15 is advantageously mounted on carousel 6 in a rotatable manner about its own axis E, coaxial in use with axis A of the relative bottle 2. In greater detail, peripheral portion 11 of carousel 6 has a plurality of through holes 16 equally spaced angularly about axis B, and a plurality of support sleeves 17, each protruding downwards from the edge of a relative hole 16; in the example shown, each support sleeve 17 is secured to the bottom face of the edge of the relative hole 16 by screws 18 and extends coaxially with a relative axis E.
Each support plate 15 is secured on top of a relative rotating element 19 engaging both the relative hole 16 and support sleeve 17 in a rotatable manner about relative axis E.
Each support device 13 further comprises an electric motor 20 having a casing 21, coaxially secured to a bottom end of the relative support sleeve 17, and an output shaft 22 supported in a rotatable manner by the casing 21 and coupled to a bottom end of the relative rotating element 19.
In practice, electric motor 20 and rotating element 19 of each handling unit 12 define actuator means for rotating a bottle 2 about its axis A during its movement along path P together with carousel 6.
Thanks to this type of arrangement, each bottle 2 has, in use, a revolution motion about axis B together with carousel 6 and a rotary motion about its own axis A as a result of the torque imparted by electric motor 20 to rotating element 19 and support plate 15.
Filling device 14 of each handling unit 12 basically comprises a support block 23 secured, in a manner known per se and not shown, to the carousel 6 and terminating, towards the bottle 2, with a hollow body 24, in the example shown having a tubular configuration; filling device 14 of each handling unit 12 further comprises a filling head 25 engaging hollow body 24 in a fluid-tight manner and adapted to cooperate with the top neck 4 of the relative bottle 2 to perform the filling operation.
In particular, each filling head 25 defines a filling mouth 26 and has a lower end 25a facing the top neck 4 of the relative bottle 2 and provided with a gasket (known per se and not shown).
Each filling head 25 is supported by the relative support block 23 in a rotatable manner about the relative axis E; each filling head 25 is also supported by the relative support block 23 in a displaceable manner along the relative axis E between a rest position (not shown), in which it has its lower end 25a spaced from the top neck 4 of the relative bottle 2, and a filling position (
In practice, each filling head 25 is supported by the relative support block 23 in an idle manner about axis E and can be displaced along the same axis between the rest position and the filling position; in this way, when a filling head 25 is set in the filling position, rotation of the relative support plate 15 about its axis E is transmitted, through the relative bottle 2, to the filling head 25, which is also driven to rotate about the axis E, so performing a guiding and supporting action on top neck 4 of the bottle 2.
Each filling head 25 defines a central conduit 27, a first annular conduit 28 extending around the conduit 27, and a second annular conduit 29 formed between the side wall of the filling head 25 and the outer side wall of the conduit 28.
Support block 23 of each filling device 14 internally defines at least three different fluid circuits, known per se and only schematically shown in
According to one important aspect of the present invention, each bottle 2 is in use rotated about its axis A, by activating the relative electric motor 20, while the bottle 2 is filled with the pourable product by the relative filling device 14.
Thanks to this additional rotation of the bottle 2 about its axis A during the revolution movement of the same bottle 2 about axis B, it is possible to obtain the following effects:
Both these effects permits to obtain a significant reduction in the formation of foam at the end of the filling operation.
According to a possible alternative not shown, each support device 13 may be defined by gripping means acting on the top neck 4 of a bottle 2 to retain it in a suspended position. In this case, the rotary motion of each bottle 2 about its axis A may be obtained by an electric motor having a casing, secured to the support block 23 of the relative filling device 14, and an output shaft connected to the relative filling head 25 and to the gripping means. In practice, in this case, the electric motor would be carried by the relative filling device 14.
According to another important aspect of the present invention, machine 1 further comprises a labelling unit 40 arranged peripherally with respect to carousel 6 and configured to feed a succession of labels 41 to the respective handling units 12 while such units are advanced along path P by carousel 6 and pass by the labelling unit 40.
As visible in
With particular reference to
In the example shown, labels 41 are of the pressure-sensitive type and are originally affixed to web 45 at spaced apart positions.
Supply assembly 44 basically comprises a supply reel 47, off which web 45 is unwound, and a plurality of rollers 48, about which the web 45 is wound to be guided and supplied along path Q; at least one of the rollers 48 is motorized to drive web 45 off the supply reel 47 and towards transfer station 42 of carousel 6.
In the embodiment shown in
According to a possible alternative not shown, labels 41 may be integral parts of a web, which is then cut by cutting means at the transfer station 42 to feed a succession of labels 41 to the bottles 2 on carousel 6.
In order to allow application of each label 41 on the corresponding bottle 2, the latter is rotated about its axis A by activating electric motor 20.
As it will be explained in greater detail hereafter, the application of each label 41 on the corresponding bottle 2 is performed after pressurization of such bottle 2 by opening valve 32 of the relative pressurization circuit 31.
Operation of machine 1 will now be described with reference to the filling of one bottle 2, and therefore to one handling unit 12, and as of the instant in which such bottle 2 is received by support device 13 of the handling unit 12 from input star wheel 7 in order to be filled with the pourable product.
In this condition, the bottle 2 is centered with respect to the relative filling device 14 by moving the filling head 25 from the rest position to the filling position. In particular, the gasket of the lower end 25a of the filling head 25 contacts the top neck 4 of the bottle 2, which reaches a position coaxial with the filling head 25. In practice, the axis A of the bottle 2 is coaxial with the axis E of the filling head 25.
At this point, valve 32 of pressurization circuit 31 is opened (the valve of product circuit 30 and valve of decompression circuit 35 are in a closed condition) and is maintained in that condition up to the moment in which pressure in the bottle 2 reaches a given first value V1, for instance about 1,5 bar, adapted to make the bottle 2 sufficiently rigid for labelling. Then, the valve 32 is closed.
In the meantime, the handling unit 12 reaches transfer station 42, where a label 41 is supplied by labelling unit 40 to the bottle 2; in order to allow application of the label 41 on the bottle 2, the latter is rotated about its axis A by activating electric motor 20. In particular, in this stage, rotary motion imparted by output shaft 22 of electric motor 20 to rotating element 19 and support plate 15 is transmitted to the bottle 2 and from the latter to the filling head 25, which is in contact with the top neck 4 of the bottle 2 and is supported in an idle condition by support block 23.
Once the label 41 has been applied on bottle 2, a further pressurization step is carried out by opening valve 32 of pressurization circuit 31, which is maintained in the open condition up to the moment in which pressure in the bottle 2 reaches a given second value V2, for instance about 6 bar, higher than first value V1 and defining the requested condition for the filling operation with the carbonated liquid. Then, the valve 32 is again closed. By opening the valve of product circuit 23, the actual filling of the bottle 2 with the product can be started. This step ends when the product reaches the desired level in the bottle 2.
During this step, electric motor 20 is again activated to rotate the bottle 2 about its axis A.
Therefore, the bottle 2 is subjected to a revolution motion about axis B and a rotary motion about axis A. Thanks to this double rotation about axes A and B, the bottle 2 can be filled at high speed with a reduced formation of foam. As a matter of fact, the centrifugal force caused by this additional rotation about axis A generates an additional pressure on the product in the bottle 2, which entraps the carbon dioxide into the product. Moreover, the product comes down into the bottle 2 along the lateral wall thereof instead of centrally.
The next step is the decompression of the bottle 2, which is achieved by connecting the bottle 2 with decompression circuit 35. At this point, the filling head 25 can be moved to the rest position.
In the case in which the pourable product delivered to the bottle 2 is a non-carbonated liquid, the second pressurization step is not performed.
The advantages of machine 1 and the filling method according to the present invention will be clear from the foregoing description.
In particular, the filling process and the labelling process of the containers are both performed on the same machine. This solution, when compared to a traditional solution using distinct machines for performing such processes, permits to reduce:
Moreover, the step of pressurizing the containers, normally used in a filling process, is exploited in the labelling process of containers made of a deformable material, such as plastics, for permitting the application of the label directly on the container.
Last but not least, the rotation of each container about its axis, normally used in a labelling process to permit application of the label on the container, is also used in the filling operation to reduce the formation of foam and thereof to increase the filling speed. In fact, as above explained, the additional rotation of each container about its axis, during the revolution movement of the same container about the carousel axis, permits to obtain the following effects:
As shown in
The post 54 is radially delimited by an inner wall comprising an upper wide portion 57 and a lower narrow portion 58, and is engaged in a sliding manner by a shutter 59 with a tubular shape, which is mounted inside the post 54 coaxial to the axis 55.
The shutter 59 projects downwards from a lower end of the post 54, and is coupled to the post 54 by means of a deformable annular membrane 60, which is interposed between the post 54 and the shutter 59 itself.
The shutter 59 defines, together with the post 54, a tubular feeding duct 61, which extends between the post 54 and the shutter 59, and is connected to a tank (not shown) of the pourable product to be fed into the bottles 2.
The shutter 59 is axially mobile between a lowered closing position, in which the shutter 59 is arranged in contact with the wall 56 so as to be coupled to the post 54 in a fluid-tight manner and close the duct 61, and a raised opening position, in which the duct 61 itself is open.
The shutter 59 is moved to its raised opening position—and normally kept there—by a spring 62, which is mounted between the post 54 and the shutter 59 coaxial to the axis 55, and is moved to its lowered closing position, against the action of the spring 62, by an actuating cylinder 63.
The cylinder 63 is obtained in the post 54 coaxial to the axis 55, is provided with a piston 64, which is coupled to the shutter 59 in an axially and angularly fixed manner, and is connected to a known pneumatic device, which is not shown.
The shutter 59 has, furthermore, a swirler 65, which is obtained on the outer surface of the shutter 59 itself, and extends along—and around—the axis 55, so as to cause the pourable product fed along the duct 61 to have a swirling movement.
The shutter 59 defines an inner feeding duct 66, which extends inside the shutter 59, and is connected to a feeding device (not shown), which is adapted to feed a gas under pressure along the duct 66 and into the bottles 2.
The device 53 comprises, furthermore, an actuating cylinder 67 with a tubular shape, which extends around a lower narrow end 68 of the post 54, is mounted coaxial to the axis 55, and is coupled to the post 54 itself in an angularly and axially fixed manner.
The device 53 cooperates with a gripping member 69 for a bottle 2 comprising a substantially cylindrical bell 70, which is coaxial to the axis 55, extends around the cylinder 67, and is arranged with its concavity facing upwards.
The bell 70 is coupled to the cylinder 67 in an axially fixed manner and, furthermore, is coupled to the cylinder 67 in a rotary manner by interposing a rolling bearing 71, so as to rotate, relative to the cylinder 67 itself and under the thrust of an actuating device 72, around the axis 55.
The device 72 comprises an electric motor 73, which is fixed to the post 54, and is provided with an output shaft 74 having a longitudinal axis 75 that is parallel to the axis 55.
The shaft 74 is coupled to the bell 70 by means of a pair of gears 76, of which one is splined to the shaft 74 and the other is obtained on the outer surface of the bell 70 itself.
The gripping member 69 comprises, furthermore, a support plate 77, which projects downwards from the bell 70, is fixed to the bell 70, and supports a pair of holding jaws 78, which are configured to hold a relative bottle 2 in correspondence to its top neck 4.
The jaws 78 are mounted under the plate 77 and are hinged to the plate 77 so as to rotate, relative to the plate 77 itself, around respective fulcrum axes 79, which are parallel to one another and to the axis 55.
The jaws 78 are moved to a clamping position—and normally kept there—by a spring 80, which is interposed between the jaws 78, and are moved to a release position by the thrust exerted on the jaws 78 themselves by the relative bottle 2 during its insertion into the gripping member 69 or its extraction from the gripping member 69.
The cylinder 67 is provided with a pneumatically operated piston 81, which is mounted so as to slide inside the cylinder 67, extends around the lower end 68, and defines part of a filling head 82.
The head 82 axially projects downwards from the post 54 and comprises, furthermore, a gasket 83 made of an elastomer material, which has an annular shape coaxial to the axis 55, faces, in use, the top neck 4 of the bottle 2, and is coupled to the piston 81 in an axially fixed manner, so as to be moved by the piston 81 between a lowered operating position, in which the gasket 83 is coupled to the top neck 4 in a fluid-tight manner, and a raised rest position, in which the gasket 83 is arranged at a given distance from the upper neck 4 itself.
The gasket 83, furthermore, is coupled to the piston 81 in a rotary manner by interposing a rolling bearing 84, so as to rotate, relative to the piston 81 itself, around the axis 55 under the thrust of the bottle 2.
To this regard, it should be pointed out that the gasket 83 is angularly integral to a lower rotary race of the bearing 84 and that the race 85 radially extends above the gasket 83 so as to define a rotary ring 86 of a mechanical sliding gasket 87.
The gasket 87 allows the piston 81 and the gasket 83, namely the angularly fixed part and the rotary part of the head 82, to be coupled to one another in a fluid-tight manner and comprises, furthermore, a further ring 88, which is mounted above the ring 86 coaxial to the axis 55.
The ring 88 is fixed to the lower free end of a sleeve 89, which is coupled in an angularly fixed and axially sliding manner to the piston 81, and is kept in contact with the ring 86 by a spring 90, which is interposed between the piston 81 and the sleeve 89 itself.
In correspondence to the transfer stations 8, 10, the position of each gripping member 69 and, hence, of the relative jaws 78 around the relative axis 55 is selectively controlled so as to guarantee a correct pick-up and a correct release of the bottles 2, respectively.
The angular position of each gripping member 69 can be selectively controlled by means of an encoder, which is associated with the relative electric motor 73, or by means of a cam mechanism, which cooperates with the bell 70.
According to an embodiment not shown, the gripping members 69 are removed and replaced by respective lower plates, which are arranged under the relative bottles 2 and are motor-operated so as to rotate around the relative axes 55, and the rotation motion is transmitted to the filling heads 82 by means of the bottles 2 themselves. In this case, when the bottles 2 are made of PET, the bottles 2 are pressurized through the feeding duct 66 so as to have a sufficient stiffness, preferably before being caused to rotate around the relative axes 55.
Obviously, the machine 51 has all the advantages deriving from the rotation of the bottles 2 during their filling, as already described for the machine 1.
| Number | Date | Country | Kind |
|---|---|---|---|
| 12199777.9 | Dec 2012 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2013/076619 | 12/13/2013 | WO | 00 |
