Process and method of sterilizing aseptic containers

Abstract

Methods for sterilizing containers, which include sterilizing preformed, or partially preformed, aseptic containers. The method includes sterilizing the containers, heating the sterilized containers to an appropriate temperature, molding the heated containers, or partially preformed containers, by an orientation blow molding process, if necessary, and filling the molded containers with an aseptic material. The filled containers are then hermetically sealed with an aseptic closure. The sterilizing is accomplished within an enclosure completely filled with an atmosphere consisting of ozone in air, and further by bringing a sterilizing fluid consisting of ozone in oxygen, or ozone in air, or ozone dissolved in water into contact with internally disposed surfaces of the containers, and injecting the gaseous mixtures containing ozone, or ozonated water, into the empty preformed containers.

1 . A method of sterilizing and filling aseptic containers comprising the steps of: 
 a) sterilizing said containers, wherein said sterilizing step comprises bringing a sterilizing fluid selected from the group consisting of gaseous ozone in oxygen, gaseous ozone in air, and ozone dissolved in water, into contact with internally disposed surfaces of said containers;    b) heating said sterilized containers to an appropriate temperature;    c) filling said sterilized containers with an aseptic material; and    d) hermetically sealing said filled sterilized containers, each with an aseptic closure.    
   
   
       2 . The method of  claim 1 , further comprising the step of injecting ozonated gas mixtures, and/or ozonated water into partially sealed sterilized containers.  
   
   
       3 . The method of  claim 1 , wherein said containers are made of a material selected from the group consisting of: 
 a) metal glass;    b) plastic;    c) paper; and    d) composite packaging material, wherein the composite packaging material is conventional or unconventional.    
   
   
       4 . The method of  claim 1 , wherein said sterilizing, heating, filling, and sealing steps, are all performed within an aseptic enclosure containing a gaseous atmosphere at pressures slightly above the ambient condition and containing concentration levels of ozone that are at least about 10 times higher than ambient level.  
   
   
       5 . The method of  claim 1 , wherein said sterilizing fluid is produced by a device selected from the group consisting of: 
 a) conventional ozone generating device that employs relatively pure oxygen as the primary feed gas;    b) a conventional ozone generating device that employs air as the primary feed gas;    c) an unconventional ozone generating device that employs relatively pure oxygen as the primary feed gas; and    d) an unconventional ozone generating device that employs air as the primary feed gas.    
   
   
       6 . The method of  claim 1 , wherein said ozonated water is produced by dissolving ozone in water before the sterilization process.  
   
   
       7 . The method of  claim 1 , wherein said ozonated water is produced by dissolving ozone in water during the sterilization process.  
   
   
       8 . The method of  claim 1 , wherein said heating step is performed by applying a heated gas to the container, wherein said heated gas is selected from the group consisting of: 
 a) air;    b) inert gas; and    c) an inert gas mixture.    
   
   
       9 . The method of  claim 1 , wherein said sealing step is performed by feeding lids or caps sterilized within the aseptic chamber or in advance outside the aseptic chamber, and fitting the caps over mouths of said containers.  
   
   
       10 . The method of  claim 1 , further including a feedback control system for maintaining aseptic process conditions.  
   
   
       11 . The method of  claim 1 , further comprising sterilizing the outside surfaces of the containers by a means selected from the group consisting of: 
 a) ambient ozonated gas mixtures;    b) injected ozonated gas mixtures; and    c) injected solutions of ozone dissolved in water.    
   
   
       12 . A method of sterilizing and filling containers comprising the steps of: 
 a) sterilizing performs, which are to be converted into aseptic containers, wherein said sterilizing step comprises bringing a sterilizing fluid selected from the group consisting of gaseous ozone in oxygen, gaseous ozone in air, and ozone dissolved in water, into contact with internally disposed surfaces of said preforms;    b) heating said sterilized preforms to an appropriate temperature;    c) molding said heated preforms by an orientation blow molding process to form the containers;    d) filling said molded containers with an aseptic material; and    e) hermetically sealing said filled containers, each with an aseptic closure.    
   
   
       13 . The method of  claim 12 , further comprising the step of injecting ozonated gas mixtures and/or ozonated water into partially sealed sterilized containers.  
   
   
       14 . The method of  claim 12 , wherein said containers are made of a material selected from the group consisting of: 
 a) metal glass;    b) plastic;    c) paper; and    d) composite packaging material, wherein the composite packaging material is conventional or unconventional.    
   
   
       15 . The method of  claim 12 , wherein said sterilizing, heating, molding, filling, and sealing steps are all performed within an aseptic enclosure containing a gaseous atmosphere at pressures slightly above the ambient condition and containing concentration levels of ozone that are at least about 10 times higher than ambient level.  
   
   
       16 . The method of  claim 12 , wherein said sterilizing fluid is produced by a device selected from the group consisting of: 
 a) conventional ozone generating device that employs relatively pure oxygen as the primary feed gas;    b) a conventional ozone generating device that employs air as the primary feed gas;    c) an unconventional ozone generating device that employs relatively pure oxygen as the primary feed gas; and    d) an unconventional ozone generating device that employs air as the primary feed gas.    
   
   
       17 . The method of  claim 12 , wherein the ozonated water is produced by dissolving ozone in water before the sterilization process.  
   
   
       18 . The method of  claim 12 , wherein the ozonated water is produced by dissolving ozone in water during the sterilization process.  
   
   
       19 . The method of  claim 12 , wherein the heating step is performed by applying a heated gas to the preforms, wherein said heated gas is selected from the group consisting of: 
 a) air;    b) inert gas; and    c) an inert gas mixture.    
   
   
       20 . The method of  claim 12 , wherein the molding step is performed by fitting the preforms into a mold and injecting a pressurized aseptic gas or gas mixture that may or may not contain ozone into the mold.  
   
   
       21 . The method of  claim 12 , wherein said sealing step is performed by feeding lids or caps sterilized within the aseptic chamber, or in advance outside the aseptic chamber and fitting the caps over mouths of said containers.  
   
   
       22 . The method of  claim 12 , further including a feedback control system for maintaining aseptic process conditions.  
   
   
       23 . The method of  claim 12 , further comprising sterilizing the outside surfaces of the containers by a means selected from the group consisting of: 
 a) ambient ozonated gas mixtures;    b) injected ozonated gas mixtures; and    c) injected solutions of ozone dissolved in water.    
   
   
       24 . A method for automatically aseptically bottling aseptically sterilized product comprising the steps of providing a plurality of aseptically sterilized containers, and aseptically filling each of said containers with aseptically sterilized product within an enclosure filled with partially ozonated air.  
   
   
       25 . The method of  claim 24 , wherein said product is foodstuffs products or medical products.  
   
   
       26 . A method of automatically aseptically bottling aseptically sterilized product comprising: 
 a) means for providing a plurality of containers;    b) means for aseptically disinfecting the containers using ozonated gas mixtures or solutions of ozone dissolved in water; and    c) means for aseptically filling the containers with aseptically sterilized product within an enclosure filled with partially ozonated air.    
   
   
       27 . The method of  claim 26 , wherein said product is foodstuffs products or medical products.  
   
   
       28 . An aseptic processing apparatus for aseptically bottling aseptically sterilized products comprising: 
 a) a sterile tunnel for surrounding a plurality of containers filled with slightly pressurized sterile air containing ozone;    b) a conveying apparatus for moving the plurality of containers through said sterile tunnel;    c) an exterior container sterilizing apparatus, comprising a container sterilizing fluid in-feed injector, a sterilizing fluid sprayer, and conveying apparatus for sterilizing an exterior surface of each container;    d) an interior container sterilization apparatus for applying a sterilant to an interior surface of each container;    e) a product filler apparatus for filling the aseptically sterilized plurality of containers with the aseptically sterilized product;    f) a lidding apparatus for applying an aseptic closure to each container; and    g) a container discharge apparatus for removing said completed containers from the sterile tunnel.    
   
   
       29 . The apparatus of  claim 28 , further comprising a drying apparatus for activating and removing the sterilant from the interior and exterior surface of each container.  
   
   
       30 . The apparatus of  claim 28 , wherein the product is foodstuffs products or medical products.  
   
   
       31 . The apparatus of  claim 28 , wherein said sterile tunnel further comprises a plurality of partitions forming a plurality of sterilant concentration zones.  
   
   
       32 . The apparatus of  claim 28 , wherein said sterile tunnel further comprises a container zone, in which said containers are inverted during the gas or liquid phase sterilization process.  
   
   
       33 . The apparatus of  claim 32 , wherein said sterile tunnel further comprises a container zone, in which the containers are re-inverted after the sterilization or drying process.  
   
   
       34 . The apparatus of  claim 28 , further comprising a feedback control system for maintaining aseptic process control throughout the entire process.  
   
   
       35 . The apparatus of  claim 28 , wherein said sterile tunnel encloses the interior container sterilization apparatus, the activation and drying apparatus, the product filler apparatus, and the lidding apparatus, and further encloses a slightly pressurized and slightly ozonated air environment throughout the entire tunnel enclosure.