Aseptic bottle filling system

Abstract

An aseptic filling system receives preformed containers through an intake sanitizing lock into a closed system. The containers move through sanitizing and sterilizing zones to a filling and closure zone. Filled containers exit the system through a discharge sanitizing lock. Both intake and discharge sanitizing locks are subjected to flooding with sterilant each time a container enters or leaves the system and provide a seal to prevent the entry of airborne contaminants or micro-organisms when the locks are opened.

What is claimed is:  
     
         1 . An aseptic container filling system comprising: 
 a container intake station including an intake sanitizing lock for admitting a container and for preventing the entry of airborne contaminants or micro-organisms into the system during the container intake process;    at least one sanitizing zone for washing and sterilizing the container;    a filling and closing zone for filling the container with a desired product and for capping the filled container; and    a discharge station including a discharge sanitizing lock for discharging a filled container and for preventing the entry of airborne contaminants or microorganisms into the system during the filled container discharge process.    
     
     
         2 . The aseptic container filling system as defined in  claim 1 , further comprising at least one zone for rinsing the washed container.  
     
     
         3 . The aseptic container filling system as defined in  claim 1 , further comprising said intake sanitizing lock including a slidable gate for selectively covering and sealing the inlet to said sanitizing lock.  
     
     
         4 . The aseptic container filling system as defined in  claim 3 , further comprising said intake sanitizing lock including a container supporting means for transporting a container from the inlet to the sanitizing lock into the system.  
     
     
         5 . The aseptic container filling system as defined in  claim 4 , wherein said container supporting means is stoppable at a predetermined position within the sanitizing lock and along the container intake path through the sanitizing lock.  
     
     
         6 . The aseptic container filling system as defined in  claim 5 , further comprising said intake station including means for dispensing a volume of sterilant into a container positioned at the inlet to said intake sanitizing lock.  
     
     
         7 . The aseptic container filling system as defined in  claim 6 , further comprising said intake sanitizing lock admitting the container subsequent to a volume of sterilant being dispensed into the container, said container being admitted to a predetermined position to be fully enclosed within said sanitizing lock and isolated from the remaining portion of the system.  
     
     
         8 . The aseptic container filling system as defined in  claim 7 , further comprising means for flooding the intake sanitizing lock with a sterilant to completely immerse the container in sterilant within the sanitizing lock.  
     
     
         9 . The aseptic container filling system as defined in  claim 8 , further comprising means for transporting the containers through the system.  
     
     
         10 . The aseptic container filling system as defined in  claim 1 , further comprising said discharge sanitizing lock including a slidable gate for selectively covering and sealing the outlet from said discharge sanitizing lock.  
     
     
         11 . The aseptic container filling system as defined in  claim 10 , further comprising said discharge sanitizing lock including a container supporting means for receiving and transporting a container from said filling and closing zone to a container discharge staging are outside the system.  
     
     
         12 . The aseptic container filling system as defined in  claim 11 , wherein said container supporting means is stoppable at a predetermined position within said discharge sanitizing lock along the container discharge path through the discharge sanitizing lock.  
     
     
         13 . The aseptic container filling system as defined in  claim 12 , wherein said slidable gate moves to uncover the outlet of the discharge sanitizing lock and the container supporting means moves the container to the discharge staging area.  
     
     
         14 . The aseptic container filling system as defined in  claim 13 , further comprising means for flooding the discharge sanitizing lock with sterilant subsequent to said container supporting means returning to its position to receive a container from said filling and closing zone.  
     
     
         15 . The aseptic container filling system as defined in  claim 14 , further comprising means for purging said discharge sanitizing lock of sterilant.  
     
     
         16 . The aseptic container filling system as defined in  claim 15 , further comprising means for purging said discharge sanitizing lock with sterilized air.  
     
     
         17 . The aseptic container filling system as defined in  claim 1 , further comprising means for pressurizing the system.  
     
     
         18 . The aseptic container filling system as defined in  claim 17 , further comprising pressurizing the system to about 3 inches H 2 O.  
     
     
         19 . The aseptic container filling system as defined in  claim 1 , further comprising said filling and closing zone including cap sanitizing means for admitting the caps to the system in an isolated manner and for preventing the entry of contaminants or micro-organisms during the cap delivery process.  
     
     
         20 . A method for aseptically filling a container comprising the steps of: 
 partially filling the container with a sanitizing agent;    receiving the partially filled container through an intake air lock into an intake chamber;    completely submersing and filling the partially filled container with sanitizing agent in the intake chamber;    moving the submersed container through the intake chamber;    evacuating the cleansing agent from the container;    filling the container at a filling station with a predetermined volume of a desired liquid;    sealing and capping the filled container; and    discharging the filled container through an exit air lock.    
     
     
         21 . The method for aseptically filling a container as defined in  claim 20 , further including the step of rinsing the evacuated container.  
     
     
         22 . The method for aseptically filling a container as defined in  claim 20 , further including the step of drying the rinsed container.