Method and Apparatus for Hub and Spoke Aseptic Processing
Embodiments of hub and spoke aseptic processing system are disclosed. In one embodiment of the current invention, a spoke aseptic processing system aseptically unloads an aseptic product from an aseptic container. The aseptic product is aseptically transported in the aseptic container from a remote site. One or more pre-filtered dilution base products are sterilized. The aseptic product and the sterilized base products are sent to an aseptic pressurized blending unit to form a final product according to a predefined formula without breaking sterilization. The final product is aseptically packaged to a finish product without break the sterile chain. In other embodiments of the current invention, a monitor and tracking system is connected with the system to monitor, track and log aseptic information. The information collected can be further uploaded to a network connected central database.
The disclosed embodiments relate generally to aseptic processing, and, more particularly, to methods and apparatus for hub and spoke aseptic processing.
BACKGROUNDThere has been a significant market growth and associated technical development in the area of aseptic processing. Traditionally, sterility was achieved through the canning process by putting the product in a container first and heating the product and the container together. During the canning process, a lot more energy is required to heat completely the product inside the container, resulting in loss of nutrition. In contrast, during aseptic process the product is heated outside the container in a continuous, closed system, cooled and then placed into a previously sterilized container. When a food product is aseptically processed, it passes through a thin pipe where it is rapidly heated to kill pathogens before quickly cooled. The short heating time is sufficient to kill germs while minimizing the quality degradation to the food nutrition. Further, since the food is filled at ambient temperatures, containers can be made of different low-cost and light-weighted materials, such as films and paperboards.
Despite the many benefits of aseptic processing, the current aseptic processing system suffers some disadvantages. The current aseptic processing facilities aseptically process the raw materials, sterilize the product, and aseptically package the product. The aseptic plant houses the aseptic processing and aseptic packaging together or close by. The cost to establish such a full aseptic plant is quite high. The equipment cost and facility requirements for a full aseptic processing establishment require a large amount of initial investment. Such burden hinders further growth of aseptic processing and limits the flexibility of aseptic processing.
The present invention provides a hub-and-spoke system that significantly reduces the cost of establishing an innovative spoke aseptic processing facility. An aseptic packaging spoke system is provided such that aseptic products can be transported from a remote aseptic hub facility and packaged to final products without breaking the sterility chain, which starts from the beginning of the aseptic processing to the end of aseptic packaging. The spoke aseptic processing system is metered and tracked by an aseptic information system. The aseptic information system can also be connected with a centralized information system.
SUMMARYEmbodiments of hub and spoke aseptic processing system are disclosed. In one embodiment of the current invention, a spoke aseptic processing system aseptically unloads an aseptic product from an aseptic container. The aseptic product is aseptically transported in the aseptic container from a remote site. One or more pre-filtered dilution base products are sterilized. The aseptic product and the sterilized base products are sent to an aseptic pressurized blending unit to form a final product according to a predefined formula without breaking sterilization. The final product is aseptically packaged to a finish product without break the sterile chain.
In another embodiment of the current invention, aseptic flavor doses are aseptically added to the final product without breaking sterilization. In another embodiment of the current invention, an aseptic balance tank is used to receive the final product aseptically from the blending unit before sending the final product to the filling unit. In one other embodiment of the current invention, a backup sterilization system is used to re-sterilize the aseptic product if the system detects that the sterilization is compromised. In one other embodiment of the current invention, a second aseptic pressurized blending tank is provided such that the aseptic filling and packaging unit receives continuous final product from one of the blending unit. When one of the aseptic blending unit unloads the entire final product, it restarts to receive ingredients to produce new batches of final product. At the same time, the other blending unit would have finished properly blending all the ingredients and starts to feed the filling unit or the balance unit so that the system does not need to wait for the other blending unit to finish blending new final products.
In other embodiments of the current invention, a monitor and tracking system is connected with the system to monitor, track and log aseptic information. A meter and control system is connected with aseptic spoke system to control and measure the flow rate of all the ingredients. In one embodiment of the current invention, the information collected from the monitor and tracking system can be further uploaded to a network connected central database. The monitor and tracking system and the meter and control system can be further connected via a network to a central aseptic center to receive information from other sites and to update information to the central aseptic database.
Reference will now be made in detail to some embodiments of the invention, examples of which are illustrated in the accompanying drawings.
As shown in
Furthermore,
Aseptic product 142 unloaded from transportation 141 can be held in an aseptic holding tank or directly fed into aseptic blend tank 145. Spoke system 140 has two additional components to sterilize pre-filtered water and liquid sweetener. Water sterilizer 143 sterilizes pre-filtered water and sends the sterilized water to aseptic blend tank 145. Sweetener sterilizer 144 sterilizes pre-filtered liquid sweetener and sends the sterilized liquid sweetener to aseptic blend tank 145. In one novel aspect, aseptic product 142, water sterilizer 143, and sweetener sterilizer 144 are all metered and controlled by a central monitor and track system 151. The ingredients, including the aseptic product, the sterilized water and the sterilized sweetener are metered by the individual volume equipments of the finished product according to a predefined formula.
Aseptic blend tank 145 is an aseptic pressurized blending tank to mix properly the ingredients into the final dilution without breaking sterility. The properly blended final product is sent to aseptic balance tank 146 where the final product is being held before sending to the filling equipment. In one novel aspect of the current invention, there are two aseptic pressurized blending units such that when one blending unit finishes blending the product and sending the final product to the aseptic balance tank, spoke system 140 meters the ingredients into the second aseptic blending unit. With a second blending unit, aseptic balance tank 146 can be fed by two blending units alternatively without waiting for blending process. When the first aseptic blending unit empties its final product, the second aseptic blending unit would have finished blending its final product such that it can feed aseptic balance tank 146 while first aseptic blending unit starts to take in ingredients or blending the ingredients. Alternatively, the second aseptic blending unit upon finishing blending can send the final product to the first aseptic blending unit, which sends the finished product to aseptic balance tank 146.
Aseptic balance tank 146 sends the final product to aseptic filler 147 to packaging the final product to finished products. Aseptic filler 147 can fill the final product to Bric-Pak (juice boxes), bags, bottles or any other aseptic packages without breaking sterility.
In one novel aspect, spoke system 140 also includes backup sterilizer 148. Backup sterilizer 148 can re-sterilize aseptic product 142 when spoke system 140 detects that sterility of aseptic product 142 might have been compromised. Upon detections of possible compromise of sterility of aseptic product 142, spoke system 142, instead of sending it directly to aseptic blend tank 145, sends aseptic product 142 to backup sterilizer 148. Backup sterilizer 148 takes aseptic product 142, re-sterilizes it and then sends the re-sterilized aseptic product to aseptic blend tank 145. For example, spoke system 140 has flow meters in the pipes that monitor flow rate and pressure of the system. If at any time, the flow meters detect that the flow rate or pressure from the aseptic container or from the unloading tank drops below a predefined threshold level, spoke system 140 will close all valves. The aseptic product from the container or the unloading tank will be removed and sent to backup sterilizer 148 to insure sterility. Other information may also indicate compromise of sterility of the aseptic product.
All the ingredients and equipments, including pumps, valves and tanks in spoke system 140 are metered and controlled by meter and control system 152. Meter and control system 152 includes flow meters, valve and pump controllers, and ingredient formula units. The flow meters measure flow rate and pressure of each components of spoke system 140. The ingredient formula units control the components in the spoke system according to a predefined formula or specification. The predefined formula or specifications can be dynamically updated through meter and control system 152. The equipment components and ingredients are also further monitored and tracked by monitor and track system 151. Monitor and track system 151 collects, monitors and tracks aseptic information about spoke system 140. Such aseptic information includes an origination hub information, destination spoke site information, quantity information of the aseptic product, transportation company and transportation route information, a bill of laden, a product number from the remote site, a certificate of analysis from the remote site, a product specification, product batch information from the remote site, and formula information of the final product. Monitor and track system 151 can further take aseptic information from meter and control system 152, such as flow rate, pressure and other available information collected. The aseptic information can be updated manually or automatically. Monitor and track system 151 can further dynamically adding, deleting or updating entries of aseptic information being tracked.
In one novel aspect of the current invention, as further shown in
The aseptic product transported aseptically by transportation 201 from a remote site is received at aseptic spoke system 200. The aseptic product in different aseptic containers can be unloaded to aseptic transfer platform 202, which is connected to one or more blending units, or to aseptic holding tank 203, which is also connected to the one or more blending units.
Central control system 280 has two subsystems: monitor and track subsystem 281 and meter and control subsystem 282. Monitor and track subsystem 281 and meter and control subsystem 282 can reside in one single box, or can reside in different computers while being connected via dedicated physical links or through a network. Monitor and track subsystem 281 monitors and tracks aseptic information of aseptic spoke system 200. Meter and control system 282 measures and controls the flow of aseptic spoke system 200.
Other components of aseptic spoke system 200 include sterilization system for one or more pre-filtered products, such as water and liquid sweeteners. Aseptic pump 235 aseptic pumps pre-filter water to water-sterilization system 204. The sterilized water is pumped by aseptic pump 236 to be sent to a blending unit via valve 263. Liquid sweeteners unloaded from transportation 209 through aseptic pump 237. The pre-filtered liquid sweeteners were pumped into sweetener sterilization system 205 through aseptic pump 237. In one embodiment of the current invention, the sterilized liquid sweeteners was pumped to aseptic buffer 207 through aseptic pump 238. The sterilized liquid sweeteners in aseptic buffer 207 can be sent to a blending unit through valve 263 via aseptic pump 239. In one embodiment of the current invention, water sterilization system 204 uses Reverse Osmosis (RO) and Ultra Violet (UV) technologies. Liquid sweeteners are heat process to achieve sterility in Liquid sweetener sterilization system 205.
In one embodiment of the current invention, aseptic flavor doses are added to the aseptic final product via aseptic dose flavor system 208. Aseptic doses can be sent to an aseptic blending unit through valve 264 via aseptic pump 240.
All the ingredients are controlled by central control system 280 to be sent to an aseptic blending unit according to a predefined formula. The aseptic product unloaded from either aseptic transfer platform 202 or aseptic holding tank 203 is pumped to an aseptic blending unit via valve 252. Valve 252 also connects with the output of backup sterilization system 206 when detecting compromised sterilization. The sterilized pre-filtered base products, such as water and liquid sweeteners together with aseptic flavor doses are sent to a blending unit via valve 255. Valve 255 connects to valve 264, which also connects to aseptic pump 240 that pumps aseptic flavor doses and valve 263. Valve 263 connects to aseptic pumps 236 and 239, which pumps sterilized water and sterilized liquid sweeteners, respectively. The aseptic blending unit receives the right amount of each ingredient and properly blends them without breaking the sterility chain.
In one embodiment of the current invention, aseptic spoke system 200 includes two aseptic blending units: first aseptic blending unit 211 and second aseptic blending unit 212. The outputs of first aseptic blending unit 211 and second aseptic blending unit 212 both connects to valve 260, which connects to aseptic pump 244 that pumps the final products to aseptic balance tank 213. The advantage of having two aseptic blending units is to continuously feeding aseptic balance tank 213 and aseptic filler 214 such that the packaging of the finishing product operates continuously without stopping to wait for one aseptic blending unit while blending. In one embodiment of the current invention, second aseptic blending unit 212 can also send its final product to first aseptic blending unit 211 via valves 259, 256 and 257.
As exemplary illustrated in
Similarly, second aseptic blending unit 212 receives all its ingredients through valve 254. Valve 254 receives aseptic product by connecting to valve 253. Valve 253, connecting to valve 252, receives aseptic product either directly from aseptic transfer platform 202 or aseptic holding tank 203, or from outputs of backup sterilization system 206. Valve 254 also receives sterilized base products and aseptic flavor doses by connecting to valve 255. Valve 255 connects to valve 264, which in one end connects to receive aseptic flavor doses, and in the other end connects to valve 263 to receive sterilized dilution base products. Through valve 254, second aseptic blending unit 211 receives all ingredients according to a predefined formula and properly blends them without breaking sterility chain. Once all ingredients are blended, aseptic pump 241 sends the final product to aseptic balance tank 213 through valves 259, 260 and 261.
In one embodiment of the current invention, when a single strength aseptic product is received, the single strength aseptic product is sent directly to aseptic balance tank 213 without going an aseptic blending unit. When a single strength aseptic product is received, valve 253 sends the aseptic product to valve 258, which opens to valve 261 directly. Valve 261 opens to send the single strength aseptic product to aseptic balance tank 213 without going through an aseptic blending unit.
Aseptic balance tank 213 receives properly blended final product from an aseptic blending unit or single strength aseptic product through aseptic pump 244. Valve 262, connecting with aseptic balance tank 213 meters and controls the final product. Aseptic pump 243, connecting to aseptic filler 214, pumps final products from aseptic balance tank 213 to aseptic filler 214. Aseptic filler 214 fills the aseptic final product into aseptic packages without breaking the sterility chain.
In one embodiment of the current invention, flow meters measure and control the amount of products sending through the system. The flow rate and amount are also recorded within the network for documentation and validation.
All aseptic valves, aseptic pumps, aseptic flow meters are connected to central control system 280 and are computer controlled. Central control system 280 controls the aseptic valves, aseptic pumps and aseptic flow meters according to a predefined formula. The predefined formula can be dynamically updated. In one embodiment of the current invention, central control system 280 is connected to network 270, which can be connected further to other information or control systems of different sites.
Once the ingredients are aseptically blended, the process moves to step 332. Step 332 sends the properly and aseptically blended final product to the balance unit. Step 333 sends the final product in the balance tank to the filling unit. Step 334 takes final product from the filling unit and aseptically packages it to the finish product without breaking the sterility chain. After sending the final product to the balance unit, the system moves to step 335 to determine whether the blending tank is empty by sending the entire final product to the balance unit. If step 335 determines that the blending tank is empty, it moves to step 336. Step 336 marks the blending tank as available. The blending tank is now ready to take in new ingredients.
Although the present invention has been described in connection with certain specific embodiments for instructional purposes, the present invention is not limited thereto. Accordingly, various modifications, adaptations, and combinations of various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the claims.
Claims
1. A method, comprising:
- aseptically unloading an aseptic product from an aseptic container, wherein the aseptic product is aseptically transported in the aseptic container from a remote site;
- sterilizing one or more pre-filtered dilution base products;
- blending the aseptic product with one or more sterilized dilution base products to form a final product according to a formula without breaking sterilization; and
- packaging the final product aseptically without breaking a sterile chain.
2. The method of claim 1, wherein the dilution base products include water and liquid sweeteners.
3. The method of claim 1, wherein the unloading involves connecting the aseptic container with a sterilized unloading hose, wherein the sterilized unloading hose comprises a first opening end connecting to the aseptic container and a second opening end connecting to a valve, and wherein the first opening end and the second opening end have different size.
4. The method of claim 1, wherein aseptically unloading the aseptic product comprises connecting an aseptic valve to the aseptic container, and wherein the aseptic valve is either a one-time aseptic valve or a valve being externally sterilized before connecting to the aseptic container.
5. The method of claim 1, further comprising:
- adding aseptic flavoring doses during the blending process.
6. The method of claim 1, further comprising:
- checking the aseptic product to determine whether the sterilization of the compound aseptic is comprised; and
- unloading the aseptic product to a backup sterilizing unit and re-sterilizing the aseptic product if the sterilization of the aseptic product is compromised.
7. The method of claim 1, further comprising:
- monitoring and tracking one or more aseptic information, wherein the aseptic information comprises: origination hub information, destination spoke site information, quantity information of the aseptic product, transportation company and transportation route information, a bill of laden, a product number from the remote site, a certificate of analysis from the remote site, a product specification, product batch information from the remote site, and formula information of the final product.
8. The method of claim 7, further comprising:
- sending the tracking information to a preconfigured aseptic information center.
9. The method of claim 1, further comprising:
- automatically metering and controlling a filling volume requirement of one or more of ingredients according to the formula, wherein the ingredients comprises: the aseptic product, the dilution base products and flavoring dosing products.
10. The method of claim 1, wherein the formula can be dynamically updated.
11. An apparatus, comprising:
- an aseptic unloading hose, which connects to an aseptic container and a first valve, wherein the aseptic container contains an aseptic product that is aseptically transported from a remote site,
- one or more sterilization units, which sterilize one or more pre-filtered dilution base products;
- an aseptic pressurized blending unit, which blends the aseptic product with one or more sterilized dilution base products to form a final product according to a formula without breaking sterilization; and
- an aseptic filling unit, which aseptically fills a plurality of aseptic packages with the final product without breaking a sterile chain.
12. The apparatus of claim 11, wherein the dilution base products include water and liquid sweeteners.
13. The apparatus of claim 11, wherein the aseptic unloading hose has a first opening end and a second opening end, wherein the first opening end and the second opening end have different size, and wherein the second opening is sized to connect to the first valve.
14. The apparatus of claim 11, further comprising:
- a second aseptic valve, which connects to the aseptic pressurized blending unit and an aseptic flavoring dose source, wherein one or more aseptic flavoring doses are added to the aseptic pressurized blending unit.
15. The apparatus of claim 11, further comprising:
- a backup sterilization unit, which sterilizes the compound aseptic product when detecting sterilization of the aseptic product is compromised.
16. The apparatus of claim 11, further comprising:
- an unloading platform upon which the aseptic containers are placed and weighed before unloading the aseptic product.
17. The apparatus of claim 11, further comprising:
- an aseptic pressurized balance unit, which connects to the aseptic pressurized blending unit and the aseptic filling unit, and wherein the final product is first received at the aseptic pressurized balance unit before being sent to the aseptic filling unit.
18. The apparatus of claim 11, further comprising:
- an aseptic holding tank that connects to the aseptic container to unload and to hold the aseptic product before sending the aseptic product for further processing.
19. The apparatus of claim 11, further comprising:
- a second blending unit that aseptically blends aseptic product with one or more sterilized dilution base products to form the final product according to the formula without breaking sterilization, wherein the second blending unit together with the blending unit provide continuous final product flow to the aseptic filling unit.
20. The apparatus of claim 11, further comprising:
- a monitor and a plurality of tracking units, which monitor and track one or more aseptic information, wherein the aseptic information comprises: origination hub information, a destination spoke site information, quantity information of the aseptic product, transportation company and transportation route information, a bill of laden, a product number from the remote site, a certificate of analysis from the remote site, a product specification, product batch information from the remote site, and formula information of the final product.
21. The apparatus of claim 11, further comprising:
- a communication unit, which sends the aseptic information to a preconfigured aseptic information center.
22. The apparatus of claim 11, further comprising:
- a plurality of automatic meter and control units, which automatically meter and control a filling volume requirement of one or more of ingredients according to the formula, wherein the ingredients comprises: the compound aseptic product, the dilution base products and flavoring dosing products.
23. The apparatus of claim 11, wherein the formula can be dynamically changed.
Type: Application
Filed: Jun 21, 2013
Publication Date: Dec 25, 2014
Inventors: Scott Eckman (St. Charles, IL), James E. Hurley (Western Springs, IL)
Application Number: 13/924,327
International Classification: B65B 55/12 (20060101); B65B 59/00 (20060101);