Method and Apparatus for Hub and Spoke Aseptic Processing

Abstract

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.

What is claimed is: 
     
         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.