Patent Application
20050252176
“Not Applicable”
“Not Applicable”
“Not Applicable”
1. Field of Invention
This invention relates generally to aseptic packages for food products and systems and methods for aseptically packaging food products.
2. Description of Related Art
The aseptic packaging of processed products, such as foods, using flexible packaging materials, e.g., polymeric films, is commonly accomplished by various techniques. One such technique is sometimes referred to as a “bag-in-box.” In that technique aseptically processed products are filled by a machine into irradiated bags through a multi-component spout that is integral with the bag. Usually the spout is on the bag only to facilitate filling and thus brings no value to the finished package. The other common technique is accomplished on a “form, fill and seal” apparatus, wherein roll stock is used to produce the pouches.
While the prior art techniques and packages used thereby are generally suitable for their intended purposes they nevertheless leave much to be desired from one or more of the following standpoints, speed of operation, ability to handle a range of package sizes and shapes, complexity of the packages (e.g., necessity for an otherwise non-functional spout as a part of the package to effect its filling), susceptibility to leakage of the resulting packages.
In U.S. Pat. No. 5,210,993, whose disclosure is also incorporated by reference herein, there is disclosed a fill and seal machine for sealing plural pouches of a saddle-bag type configuration. Pouches of that type are disclosed in U.S. Pat. No. 5,237,799, whose disclosure is also incorporated by reference herein. A machine utilizing the teachings of those patents is commercially available from the assignee of this invention under the trade designation GL90. That machine is particularly suitable for the food-service industry since it can be used to fill flexible packages with a variety of products that are thermally processed after filling to render them shelf-stable. For example, the GL90 machine is versatile enough to be used in what are referred to as “hot-fill and hold” processes to create shelf-stable products. Products that fall into this category are high acidic, e.g., pH of 4.3 or lower, products and low water activity formulations. As presently configured the GL90 machine is not suitable to package low or high acid aseptically processed products at ambient temperatures direct from the process.
Numerous patents disclose aseptically sealed flexible packages and systems and methods for aseptically sealing products in flexible packages. For example, U.S. Pat. No. 4,194,622 (Lewis) discloses a sterilizable package wherein a slit extends along the front thereof from one side to the other, close to the bottom of the package. An adhesive layer is deposited over the entire length of the slit. A protective strip is disposed over the adhesive layer in order to protect it, thereby also sealing the slit. An object is inserted into the package by removing the strip and inserting the object through the slit. The package is sealed by folding it along a fold line located slightly above the adhesive to bring the adhesive into contact with the front of the package. The package is then sterilized.
U.S. Pat. No. 3,938,658 (Rohde) discloses a sterile pouch in which a film is drawn off a first roll and a narrow porous strip is drawn off a second roll. Spaced apart slits are provided in the film and the porous strip is superimposed upon and sealed to the film in a position covering the slits. The film is folded to form a pouch. The contents of the pouch are inserted from the bottom and the pouch is sealed. The pouch and contents are sterilized by a steriliant entering the pouch by way of the porous strip and the slit.
U.S. Pat. No. 5,551,781 (Wilkes) discloses a large sterilizable container having an access slit extending along a front surface thereof substantially from one side to the other at a location close to the top of the package. A porous membrane covers the access slit and a peelable interlayer is disposed between the front surface and the membrane without covering the slit. The contents' are inserted through the side of the container rather than through the access slit.
U.S. Pat. No. 5,868,244 (Ivanov) teaches a vented package wherein a slit-like vent opening 80 is provided with a gas permeable membrane to permit sterilizing gas to flow therethrough to sterilize the interior of the package and for evacuation of the gas after sterilization is complete. A seal is provided to close the vent opening after the sterilization process.
U.S. Pat. No. 4,035,981 (Braun) teaches an aseptic packing method which is of interest because it includes the use of dry radiation for sterilization of packing material. In the method taught by Braun, the packing material is shaped to form a tube that is sterilized by infrared and ultraviolet radiation and filled with a pre-sterilized food substance. The container is then stamped and sealed.
U.S. Pat. No. 4,022,324 (Schuster) teaches a sealed container wherein a breathable cover is bonded to a tray sheet. The cover comprises two panels forming an overlapping region that is covered with a breathable membrane disposed thereupon. The overlap between the two panels and the membrane form a passageway for sterilizing vapor that is impermeable to bacteria.
U.S. Pat. No. 3,783,581 (Pierce) discloses an aseptic packaging machine for packing food having an enclosed sterile chamber containing a plurality of operating stations. In the upper left of
Other U.S. patents relating to this topic are: U.S. Pat. No. 3,481,100 (Bergstrom), U.S. Pat. No. 3,532,571 (Ausnit), U.S. Pat. No. 3,761,013 (Schuster), U.S. Pat. No. 3,884,012 (Ernstsson et al.), U.S. Pat. No. 3,947,249 (Egger), U.S. Pat. No. 4,008,851 (Hirsch), U.S. Pat. No. 4,057,144 (Schuster), U.S. Pat. No. 4,194,622 (Lewis), U.S. Pat. No. 4,223,512 (Buchner), U.S. Pat. No. 4,494,357 (DiGeronimo), U.S. Pat. No. 4,524,563 (Sassi), U.S. Pat. No. 4,686,814 (Yanase), U.S. Pat. No. 4,765,118 (Akutsu et al.), U.S. Pat. No. 4,782,646 (Nantin), U.S. Pat. No. 4,979,933 (Runge), U.S. Pat. No. 5,120,993 (van Boxtel), U.S. Pat. No. 5,228,271 (Wallace), U.S. Pat. No. 5,237,799 (van Boxtel), U.S. Pat. No. 5,310,262 (Robison et al.), U.S. Pat. No. 5,378,226 (Hanifl et al.), U.S. Pat. No. 5,606,847 (Joensson et al.), U.S. Pat. No. 5,776,045 (Bodolay et al.), U.S. Pat. No. 6,070,397 (Bachhuber), U.S. Pat. No. 6,079,184 (Cassou et al.), U.S. Pat. No. 6,085,491 (Bois), U.S. Pat. No. 6,098,800 (Bennish, Jr. et al.), U.S. Pat. No. 6,162,158 (Mercer et al.), U.S. Pat. No. 6,413,350 (Boschi), U.S. Pat. No. 6,419,825 (Hahmann et al.) and U.S. Pat. No. 6,510,669 (Bellei et al.). See also published U.S. Patent Application 2003/0014945 (Danby).
This invention relates to flexible packages for use in an aseptic filling and sealing apparatus to seal products within the package under aseptic conditions and systems incorporating such packages and apparatus.
The package of this invention is formed of a flexible material, e.g., a polymeric film of one or more plies or layers, and basically comprises a bottom panel and a pair of top panels. Each of the top panels is secured to respective portions of the bottom panel along marginal edge portions thereof to form a pair of bags or pouches connected together by an intermediate section. Each of the bags or pouches has a hermetically sealed, a top end, a sealed bottom end, and a pair of sealed sides. The top end of each bag or pouch is located immediately adjacent the intermediate section of the package and is initially sealed so that the hollow interior of each of the bags or pouches is sterile. Each of the top ends of the bags or pouches are arranged to be selectively opened within the filling and sealing apparatus under aseptic conditions, whereupon the product can be introduced into the interior of each of the bags or pouches through the opened top ends of each of said bags or pouches. Each of the top panels adjacent the top ends of each of the bags or pouches includes resealable portions arranged to be sealed to said bottom panel after the products are introduced into the interior of the bags or pouches to store the products therein under aseptic conditions.
In accordance with one preferred aspect of this the package of this invention the top end of each of the bags or pouches is in the form of a free edge of the top panel and a respective strip of adhesive tape covers that free edge to initially seal the hollow interior of that bag or pouch. The tapes are removable from those free edges within the apparatus to enable the product to be introduced through the interface between those free edges and the bottom panels, whereupon the top panels of the bags or pouches can be sealed to the bottom panel along the resealable portions to store the products in the bags or pouches under aseptic conditions.
In accordance with another preferred aspect of the package of this invention the top end of each of the bags or pouches is in the form of an edge portion sealed to the bottom panel and a weakened or frangible line, e.g., a laser scored line, located below the sealed edge portion. The resealable portions comprise lines located below the weakened or frangible lines. Each of the weakened or frangible lines is arranged to be opened within the apparatus to enable the product to be introduced therethrough, whereupon the top panels of the bags or pouches can be sealed to said bottom panel along those resealable lines to store the products in the bags or pouches under aseptic conditions.
In accordance with another preferred aspect of the package of this invention, the package comprise a series of releasably connected packages.
The system of this invention basically comprising an aseptic filling and sealing apparatus and a plurality of flexible packages, like those set forth above. The apparatus includes an aseptic chamber into which the packages are introduced, a station including means for opening each of the packages within the aseptic chamber. The apparatus is arranged to introduce the product into the hollow interior of each of the bags or pouches through the opened top ends of each of those bags or pouches. The apparatus is also arranged to seal the resealable portion of the bags or pouches under aseptic conditions after the products are introduced into the interior of those bags or pouches.
In accordance with one preferred aspect of the system of this invention wherein each of the bags or pouches is initially sealed with a respective strip of adhesive tape, the apparatus is arranged to remove those tapes within the aseptic chamber to open said hollow interior of said bags or pouches. The apparatus is also arranged to introduce the product into the open bags or pouches through the interface between the free edges of the top panels of the bags and the bottom panels under aseptic conditions, and also to seal those top panels to the bottom panel along the resealable portions under aseptic conditions.
In accordance with another preferred aspect of the system of this invention wherein the top end of each of the bags or pouches is in the form of an edge portion sealed to said bottom panel and a weakened or frangible line located below the sealed edge portion, and with the resealable portions comprising lines located below the weakened or frangible lines, the apparatus is arranged to open the weakened or frangible lines within the aseptic chamber. The apparatus is also arranged to introduce the product through the opened lines under aseptic conditions and to seal said top panels of the bags or pouches to the bottom panel along the resealable lines under aseptic conditions.
The method of this invention entails filling and sealing products within flexible packages under aseptic conditions by use of an aseptic filling and sealing apparatus. The apparatus is like that set forth above. The method basically comprises: providing a plurality of packages like that set forth above. The packages are introduced into the apparatus, whereupon the opening means of the apparatus opens the top end of each bag or pouch within the aseptic chamber. Then the filling means of the apparatus is operated to introduce the product into the interior of each of the bags or pouches through the opened top ends of each of the bags or pouches under aseptic conditions. Once that has been accomplished the sealing means of the apparatus is operated to seal the resealable portion of the bags or pouches under aseptic conditions.
The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:
Referring now to
Referring to
Referring now to
The fabrication of the supply 12 of precursor packages 20 can be accomplished using any suitable flexible package making technique and equipment involving the sterilization and hermetic sealing of the bags or pouches 22A and 22B. Thus, such action will not be described herein in the interests of brevity.
In accordance with one preferred embodiment of this invention only two tape strips 38 are used for all of the saddle bag packages 20 making up the supply 12, rather than having an individual and separate tape strip closing each bag. To that end, one common tape strip 38A extends across the entire series of bags or pouches 22A on one side of the intermediate section 24 to form the strips 38 that close all of those bags 22A, while another tape strip 38B extends across the entire series of bags or pouches 22B which are located on the opposite side of the intermediate section 24. Each of the unitary tape strips 38A and 38B can be formed of any material suitable for sterilization and for maintaining the interior of the bags under hermetically sealed conditions. Moreover, the adhesive making up those strips is chosen so that it can be readily removed by peeling it off of the portions of the package to which it is initially affixed. In lieu of using adhesive tape strips, like 38A and 38B, each of the strips closing the bags can be formed of a film or some other material which doesn't include any adhesive but which is releasably secured by a layer of adhesive applied to the outer surface of the top panels 26 and the contiguous portion of the intermediate section 24.
It should be pointed out at this juncture, that the top edge portions of each of the bags 22A and 22B, need not be releasably sealed over the entire width of the package. Thus, it is contemplated that one or more portions of the top edge of the top panel is fixedly secured, e.g., welded, to the underlying bottom panel, with the unsecured portion of the top edge being releasably secured by a tape strip 38.
In any case packages 20 constructed as described above are arranged to be readily opened by peeling away or otherwise removing the tape strips 38 so that the package can be filled and sealed through the opened top of the bags 22A and 22B.
In
The top panel 26 of each of the packages 20′ is permanently sealed, e.g., heat sealed, welded, adhesively secured, etc., to the bottom panel 28 along a line 42 extending the entire width of the package 20 between the side seals 30 and 32. The seal line 42 is located at or immediately below the top edge 36. A openable, e.g., frangible, line 44 is located in the top panel 26 just below the permanently sealed line 42 to provide an openable access-way to the interior 40 of the package to enable the package 20′ to be opened, filled and then sealed. The openable line 44 can extend the full width of the package or only a portion thereof. In accordance with one preferred embodiment of this invention the openable line is a laser scored line. Other techniques can be used to provide a weakened or otherwise openable line in the top panel of the package, in lieu of a laser scored line, so long as the weakened or otherwise openable line is sufficiently strong as to maintain the hermetic seal and sterility of the hollow interior of the package before the package is introduced into the apparatus for opening, filling and sealing its bags.
It should be pointed out at this juncture that the packages described heretofore are merely exemplary of a myriad of different types of packages that can be constructed in accordance with this invention. Thus, this invention contemplates flat pouches, stand up pouches, shaped pouches, pouches with handles, pouches with fitments, tubes or spouts strategically located in the pouch and pouches with special dispensing sections. Moreover, the pouches can be formed of flexible materials having one or my layers or plies of polymeric materials, metals (e.g., foils) or other materials commonly used in the flexible packaging industry.
If the product to be packaged in either package 20 or package 20′ is desired to be packaged under aseptic conditions, that can be readily accomplished within the apparatus 100 of this invention or within any other apparatus that can open, fill and seal those packages under aseptic conditions. In particular, when using packages like 20, the apparatus 100 is configured to peel away or otherwise remove the tape strips 38A and 38B under aseptic conditions within the apparatus. Then the opened packages are filled with a food or any other product and sealed, all under aseptic conditions within the apparatus. When using packages like 20′, a slightly modified apparatus 100′ is provided and is configured to break open the frangible or laser scored line 44.
Referring now to
The packages that enter into the chamber 102 are drawn onto a support assembly 108, only a portion of which is shown in
Heated air and 31% atomized (vapor phase) hydrogen peroxide is introduced into a sterilization chamber 106 located within the enclosure 102 via a main conduit 108 and communicating branch conduits 110 to pressurize the chamber 106 to approximately 0.1 inch of water at temperature of approximately 145° F., thereby sterilizing the exterior portions of the top ends of the bags 22A and 22B of the packages 20. The packages 20 are now ready to have their bags 22A and 22B opened. To that end, a tape removal device, including a pair of tape take-up reels 112A and 112B (
The now opened bags 22A and 22B are pulled out of the sterilization chamber and into a filling and sealing chamber 114 making up the filling and sealing section of the apparatus. The chamber 114 is also provided with heated air and the hydrogen peroxide via a conduit 116 that is coupled to the conduit 108. A valve 118 is located in conduit 108 for reasons to be described later. A set of stainless steel opening fingers (not shown) are located within the chamber 114 to pull the bags 22A and 22B open so plural filling valves or tubes can fill the now opened bags. In particular, a pair of filler tubes or valves 120A are located in the filling and sealing chamber 114 and are arranged to be reciprocated into the now open top ends of two serially located bags 22A, to introduce the aseptically processed product P, e.g., food, into the hollow interior 40 of those bags. A similar pair of filling valves or tubes are provided to fill the associated two serial connected bags 22B. The aseptically processed product is provided from a source (not shown) coupled to the filler tubes or valves via a common conduit 122. Once the bags 22A and 22B have been filled, the filling tubes reciprocate, i.e., retract out of the bags, and the package 20 holding the now filled bags is pulled to a sealing station 124 also located within the filling and sealing chamber 114.
The sealing station 124 includes plural pairs of heated sealing bars 126. The one pair of bars are opposed on opposite sides of the bag 22A and a similar pair of bars are opposed on opposite sides of bag 22B. These opposed sealing bars are arranged to be brought together to sandwich the top and bottom panel of the particular bag between them to seal the top edge of the top panel to the underlying portion of the bottom panel. This completes the sealing of the bags 22A and 22B of the package 20, whereupon the package looks something like that shown in
As the series of filled and sealed packages exit the filling and sealing chamber, their bags 22A and 22B are severed from the intermediate section 24, at a cut-off station 134, and the intermediate section is taken up by a take-up reel 136. The cut-off station basically comprises plural knife blades (not shown) which sever the serially connected filled packages 20 from one another by cutting the material making up the bottom panel between the side heat seals 32 of the bags 22A and 22B of the leading package 20 and the side heat seals 30 of the bags 22A and 22B of the next succeeding package 20. The take up reel 132 serves as the means for pulling the series of packages 20 through the apparatus 100.
The resulting bags 22A and 22B are now separate from each other and can be conveyed via a conveyor or some other mechanism (not shown) to a packaging station wherein they are provided in cartons or other shipping containers.
In
As can be seen the bags 22A and 22B of the package 20′ are brought into the sterilization chamber 106 where a pair of rollers 140A and 140B are located on opposite sides of a portion 142 of the support apparatus holding the intermediate section 24 of the package 20′. The support apparatus holding the intermediate section 24 of the package between the rollers 140A and 140B includes a pair of outwardly projecting tapered edges 142A and 142B which are aligned with the weakened lines 44 of the bags 22A and 22B. The roller 140A engages the portion of the package contiguous with the weakened laser scored line 44 of the bag 22A to force it against the tapered edge 142A to cause that line to break or rupture. At the same time the other roller 140A engages the portion of the package contiguous with the weakened laser scored line 44 of the bag 22B to force it against the tapered edge 142B to cause that line to break or rupture. Once the package's bags 22A and 22B are opened, the processing of the package continues in the same manner as described with reference to the filling and sealing of the packages 20.
In lieu of the rollers 140A and 140B to effect the opening of the weakened laser scored lines 44 of the packages 22A and 22B, the apparatus 100′ may includes stationary blunt bars 144A and 144B as shown in
The following constitutes a preferred method for effecting the filling and sealing of a series of packages constructed in accordance with this invention, e.g., packages 20 or 20′, using the apparatus 100 or 100′, respectively, of this invention. As a preliminary step, the apparatus is presterilized using vapor phase hydrogen peroxide and warm-to-hot air. The product delivery portions of the apparatus, e.g., the internal surfaces of the filling station components that will be in contact with the product, and the interface of those portions of the apparatus and the supply for the product, e.g., tanks, vats, vessels, conduits, valves, etc., are also sterilized using steam or superheated water. Other areas of importance for sterilization are the bag-sterilizing chamber 106 and the filling and sealing chamber 114. All functional measurements, determined to be critical factors for creating sterility are monitored continuously and a permanent record of these critical factors is created.
The next step entails what can be referred to as post-sterilization. In particular, after the pre-sterilization has been completed the flow of hydrogen peroxide vapor to the filling and sealing chamber is halted by the closing of the valve 118, but continues to flow to the sterilization chamber 106. Both chambers 106 and 114 will be over-pressurized and monitored as such to maintain their sterile status. Again, all critical factors for maintaining commercially sterility are monitored continuously and a permanent record, assigned to this step, is created.
The next step entails what can be referred to as “production.” In particular, the gamma irradiated supply 12 of packages 20 are pulled into the apparatus at the appropriate rate to insure that they receive the proper minimum exposure to hydrogen peroxide vapor. In the sterilization chamber 106 the bags 122A and 122B are opened either through removal of the tape 138 or film (such as occurs with packages 20), or via controlled breaking of a laser score line 44 on the top panels of each of the bags 122A and 122B (such as occurs with packages 20′). The open bags 122A and 122B advance through the sterilization chamber 106 and into the filling and sealing chamber 114, where the set of stainless steel opening fingers pull the bags open so that filling valves can descend into two to four bags. The filling valves open, fill the bags with the product P and then are closed in response to a number of aseptic filler controls options, depending on product consistency and process type. The filled bags 22A and 22B advance from the filing station to the sealing station where a set of mechanical deflator plates or bars (not shown), apply mechanical pressure to the filled bags in such a way so as to remove or substantially reduce residual air volume. Timed with the deflator system, the heated top-seal bars applies heat and pressure to the bag tops for the appropriate time to effect a hermetic seal. The sealed bags 22A and 22B advance out of the sterile filling and sealing chamber 114 to the cut-off station 134 where they are cut free from the intermediate section 24 of saddle bag arrangement and that section is removed, e.g., reeled up on the take-up reel 136. As before, all critical factors for maintaining commercially sterility and that are associated with production are monitored continuously and a permanent record, assigned to this step, is created.
The last step of the process entail what can be called a clean-in-place system. In particular, an integrated “clean in place” subsystem(not shown) automatically cleans all product delivery and process interface piping to be in accordance with industry standards.
As should be appreciated from the foregoing by those skilled in the art, the systems and methods of this invention using the packages of this invention offer various advantages over the prior art. For example, a GL90 machine configured in accordance with the teachings of this invention and utilizing the packaging of this invention (or some other system utilizing the teachings of this invention) should be able to produce finished products at a substantially higher rate than prior art systems. Moreover systems of this invention do not need to incorporate pouch cooling equipment. In this regard, use of a conventional GL90 machine for some aseptic packaging applications, e.g., the very large tomato industry, requires the use of pouch cooling equipment. Such equipment entails a significant capital investment. In contradistinction a GL90 machine configured in accordance with the teachings of this invention and utilizing the packaging of this invention eliminates the need for such cooling equipment. Moreover, the packages of this invention do not require the inclusion of a spout which would otherwise be unnecessary for the package, but which must be included to effect the filling of the package. Further still, a GL90 machine configured in accordance with the teachings of this invention (or some other system utilizing the teachings of this invention) can be used to handle a wide range of bag or pouch types, such as clear pouches, foil barrier pouches, flat pouches stand up pouches, shaped pouches, pouches with handles, pouches with fitments, tubes or spouts strategically located in the pouch and pouches with special dispensing sections. Further still the systems of the subject invention are quite flexible in terms of changeover to accommodate a variety of pouch sizes and shapes as compared to existing technology.
While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
