CN104271451B - For the method and apparatus processing sterile food product - Google Patents

Abstract

A method for processing sterilized food products, the method comprising: sterilizing an intermodal container comprising a rigid shell having a closed end with a rear and a front The elongated shape and the discharge opening in the rear closed end. The intermodal container also includes front and rear support frame assemblies supporting the rigid shell. The method may also include aseptically filling the intermodal container with the sterilized food product, and transporting the filled intermodal container via the transport vehicle while maintaining the sterilized food product under aseptic conditions. Additionally, at an emptying station, the method includes pushing the front support frame assembly upwardly to tilt the intermodal container at an angle of at least 8 degrees from horizontal and emptying the sterilized food product from the discharge opening .

Description

Method and apparatus for processing sterile food products

technical field

The present invention relates to the field of food science, and more particularly to the field of aseptic processing of food products.

Background technique

In the field of food processing, it is common to process food at one location and transport bulk quantities of food to another location for further processing or final packaging. Various methods have been developed for containing and transporting food products. For example, juice or milk is often processed at one facility and sent to another for final packaging. The two facilities may be located near each other or may be in different countries. Because food products are prone to deterioration due to microbial spoilage, various treatments are used during this transportation and storage to retard or prevent microbial growth. These include sterilizing food inside containers, hot filling clean containers, or placing sterilized food products into sterile containers. Other methods include freezing, refrigerating, or using preservatives.

Disadvantages of sterilizing the interior of containers include the cost of such containers and deterioration of the food product due to the amount of heat required. Also, due to the need to sterilize the food product at a cold point, this type of processing is common for final packaging, but not typically for bulk products. A bulk food product is a food product that is substantially larger in quantity than final retail or food service packaging. For example, bulk food products are typically larger than 50 gallons. Likewise, hot-fill is often used for final packaging, but not for bulk products.

In contrast, freezing is a typical method used to handle bulk products suitable for transport. For example, pasteurized fruit juices are often filled into 55-gallon drums, often with drum liners, and then frozen prior to shipment. Disadvantages of freezing include the energy required for freezing, the energy required to maintain frozen product during shipping and storage cycles, and the cost of drums. Additional disadvantages include potential physical and chemical changes to the product due to freezing. For example, when citrus pulp cells are frozen, the cell walls are destroyed. After thawing, the pulp cells have different physical properties compared to those that have not been frozen.

The use of chemical preservatives for certain food products has a number of disadvantages. These disadvantages include changes in consumer perception and taste. In many food products, the use of preservatives is not permitted under certain standards or by law.

For certain food products, the method of placing a sterile food product into a sterile container has many advantages over the process described above. This method is often referred to as aseptic processing. In aseptic processing, food products are pasteurized in a location considered commercially sterile. In this state, the possibility of the presence or growth of microorganisms is very low. The sterilized food product is then placed into sterile containers in such a way as to avoid the introduction of microorganisms. Aseptic processing can be used to place sterilized food products (eg, shelf-stable milk or juice) into final consumer containers or can be used to store and transport bulk food products in an aseptic state. For example, juice and tomato products are often pasteurized and aseptically filled into 300 gallon bags for storage and transport to other food handling facilities. Similarly, fruit juices may be pasteurized and aseptically filled into large stationary bulk containers (currently up to 2,000,000 gallons) for storage prior to blending and packaging.

The most common form of shipping of aseptic food products involves the use of 300 gallon bags as described above. Such bags are filled into disposable or reusable containers such as wooden boxes or reusable plastic containers, and the bags are sealed with a lid after filling. A wooden or plastic container supports the bags and allows the boxes to be stacked during shipping. The current citrus pulp is aseptically filled into such "bag-in-box" containers. Although widely used, disadvantages of this method include the cost of bags and boxes. When shipping overseas, there is an additional cost attached to returning empty boxes for further use. An additional disadvantage of this system is that the bags cannot be unloaded aseptically. At the point of use, the bag is cut open and the product is poured or pumped from the bag. Therefore, it is necessary to further pasteurize the product before final packaging.

Another method of aseptic transport involves the use of aseptic tank or rail cars and over-the-road containers. Railcars typically have a conical funnel on the bottom. This method ships tomato products by Bishopric Products Co. (formerly Cicinnati, Ohio) (Food Technology, July 1976). Tank cars are sterilized by use of steam or chemical sterilants (eg, povidone iodine) and then filled with sterile product. The food product is successfully transported from one location to another while being maintained under sterile gas pressure and in a sterile state during transportation.

For example, US Patent Application No. 3209675 discloses a device for aseptic transport of perishable liquids. The device is a transportable container sterilized by a chemical sterilant (peracetic acid) and kept pressurized during transport by using an inert gas cylinder. US Patent Application Nos. 6,030,580 and 6,277,328 also disclose methods of aseptically transporting bulk food products in transportable containers. The use of aseptic tank cars or rail cars as described in these patents overcomes the cost of bags and boxes and provides a more economical method for transporting sterile products.

Hawaii Intermodal Tank Transport LLC of Palmetto, Florida supplies aseptic intermodal containers suitable for aseptic transport of food products. This intermodal container utilizes the same principles as described above for aseptic tank cars and rail cars, but offers the added advantage of being configurable for transport by truck, rail or ship. Juice is currently being transported aseptically in such intermodal containers.

Referring to Figure 1, such an intermodal container 30 includes a cylindrical rigid shell 31 that may be approximately 20 feet long and may hold approximately 24,000 liters. The housing includes rear and front closed ends 32a, 32b in the form of shallow domes. The discharge port is located behind the rear panel access door 33 at the bottom of the rear closed end 32a. The intermodal container 30 also includes a pair of rear and front rectangular support frame assemblies 35a, 35b that support the rigid shell and allow the containers to be stacked, such as for transport via ship, or when in a storage area, for example. The container 30 may also include inwardly extending corner support arms (not shown) extending inwardly from the corners of the respective support frame assemblies 35a, 35b and attached to the rigid shell 31 . Intermodal container 30 also illustratively includes a ladder 36 carried by rear support frame assembly 35a, and a horizontally-traveling platform 37 to facilitate access to manholes and other egress and egress at the top of rigid shell 31 . In some configurations, intermodal container 30 may include an insulating layer associated with rigid shell 31 . Additionally, a portable refrigeration unit may be configured to keep the contents cool, and one or more temperature and/or pressure sensors may be configured to monitor the contents.

While providing a safe and economical method of aseptically transporting liquid food products, the use of aseptic tank cars, rail cars and intermodal containers makes them unsuitable for the aseptic transport of high-viscosity products such as tomato paste, high-viscosity pulp or Citrus pulp. A high viscosity food product may be considered a food product that does not flow easily by gravity. These products would not flow out of the tank if placed in a typical tank without a drain bottom or would be impractical to drain by gravity at such low velocity flows. This product can be pumped with the correct pump selection and can therefore be pumped into sterile containers. However, since these products do not flow easily by gravity, it is not easy to remove such highly viscous food products from such containers.

Intermodal containers also typically include aseptic fill/discharge valves for filling and discharging food products. When switching from one container to another, the hose is disconnected from one container and connected to the other. Loss of sterility due to hose disconnection and exposure to atmosphere. Thus, the hose is re-sterilized when connecting to the next container. In addition, the outside chamber of the filling valve is also sterilized before passing the sterile food product through the valve. This sterilization process can take a lot of time between containers. Because it is a manually intensive process, it is subject to user error, which can result in product contamination. Such aseptic filling of jars and containers is disclosed, for example, in US Patent Application Nos. 3,951,184 and 4,047,547, the entire disclosures of which are incorporated herein by reference in their entirety.

For example US Patent Application No. 3209675 discloses a device for aseptic transport of perishable liquids. The device is a transportable container sterilized by a chemical sterilant (peracetic acid) and kept pressurized during transport by using an inert gas cylinder. US Patent Application Nos. 6,030,580 and 6,277,328 both describe the aseptic transport of food products with chemical sterilants.

Juices and other liquid food products are currently being aseptically shipped in intermodal containers by Hawaii Intermodal TankTransport. Intermodal containers can be transported by truck, rail or ship, and they are filled and discharged through a single valve located at the lowest point of the tank. Re-sterilization of the filling line is required between each container.

Contents of the invention

In view of the foregoing background, it is an object of the present invention to provide a method for the efficient aseptic processing of food products, such as food products having a high viscosity.

These and other objects, features and advantages according to the present invention are provided by a method for processing sterilized food products comprising sterilizing an intermodal container comprising a rigid shell and a support Front and rear support frame assemblies of a rigid housing having an elongated shape with rear and front closed ends and a discharge opening within the rear closed ends. The method may also include aseptically filling the intermodal container with the sterilized food product. The method further includes transporting the filled intermodal container via the transport vehicle while maintaining the sterilized food product under aseptic conditions. At one emptying station, the method includes pushing upward on the front support frame assembly to rotate the intermodal container from horizontal to an inclination angle of at least 8 degrees and emptying the sterilized food from the discharge opening product.

Thus, large volumes of sterilized food products can be efficiently transported and emptied from intermodal containers taking advantage of gravity-based emptying. Of course, the method is particularly advantageous for such emptying when the sterilized food product comprises a viscous sterilized food product, such as like citrus pulp or other food product having an absolute viscosity greater than 500 centipoise.

Transport may include conveying the intermodal container to an emptying site via a transport vehicle. In one embodiment, pushing upwards includes causing the transport vehicle to travel on an upwardly inclined ramp. In another embodiment, urging upward includes raising the front of the transport vehicle relative to the rear of the transport vehicle.

The method may also include supplying a sterilizing gas to maintain a positive pressure within the intermodal container at least during emptying. Furthermore, a pump coupled to the discharge port may be used during the evacuation.

In some embodiments, the angle of inclination may be at least 18 degrees from horizontal, and at least 30 degrees from horizontal in other embodiments. The intermodal container may have a capacity greater than 10,000 litres, and may have a discharge opening in the lower portion of the closed end of the intermodal container.

The method may include maintaining at least one of a desired pressure and a desired temperature within the intermodal container during transportation. Additionally, the method may include at least one of recording and wirelessly transmitting at least one of the desired pressure and the desired temperature. Sterilizing may include sterilizing with at least one of water vapor and chemical sterilants.

Description of drawings

Figure 1 is a perspective view of an intermodal container as in the prior art.

Figure 2 is a flow diagram of a method for processing aseptic food products according to the present invention.

3A and 3B are schematic side views illustrating spinning and emptying, respectively, according to the method shown in FIG. 2 .

Figure 4 is a schematic illustration of a portion of another embodiment of an intermodal container according to the present invention.

FIG. 5 is a substantially enlarged portion of the rigid shell of an intermodal container as shown in FIG. 4 .

Figure 6 is a flow diagram of another method for processing aseptic food products according to the present invention.

Figure 7 is a schematic illustration of an aseptic filling station and intermodal container suitable for use according to the method shown in Figure 6 .

Figure 8 is a more detailed schematic side view of a portion of another embodiment of an aseptic filling station and intermodal container according to the present invention.

FIG. 9 is a more detailed schematic side view of the intermodal container as shown in FIG. 8 .

10 is a cross-sectional view of a film-type aseptic fitment suitable for use on an intermodal container in accordance with the present invention.

11 is a cross-sectional view of another embodiment of the membrane sterile fitment as shown in FIG. 10 .

12A is a cross-sectional view of another embodiment of the membrane sterile fitment as shown in FIG. 10 .

Figure 12B is a plan view of the shoulder portion of the membrane sterile fitment as shown in Figure 12A.

13 is a cross-sectional view of the film aseptic fitment installed on an intermodal container as shown in FIG. 10 .

Figure 14 is a cross-sectional view of the membrane sterile fitment as shown in Figure 10 after membrane rupture.

15 is a cross-sectional view of a cap aseptic fitment for use on an intermodal container in accordance with the present invention.

16 is a cross-sectional view of another embodiment of the cap-type sterile fitting as shown in FIG. 15 .

17A is a cross-sectional view of another embodiment of the cap-type sterile fitting as shown in FIG. 15 .

Figure 17B is a plan view of the shoulder portion of the cap-type sterile fitting as shown in Figure 17A.

18 is a cross-sectional view of the cap-type aseptic fitment installed on an intermodal container as shown in FIG. 15 .

Figure 19 is a side view of the cap-type sterile fitting positioned on the sterile bag as shown in Figure 15 .

20 is a side view, partially in section, of a membrane-type aseptic fitment as shown in FIG. 10 and installed on an intermodal container.

21 is a flow diagram of another method for processing aseptic food products according to the present invention.

FIG. 22 is a schematic side view of a system for spinning and emptying according to the method shown in FIG. 21 .

23 is a schematic side view of another system for spinning and emptying according to the method shown in FIG. 21 .

detailed description

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to only the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numbers refer to like elements, and primes and multiples are used to indicate similar elements in alternative embodiments.

Referring first to the flowchart 50 of Figure 2, a method for processing a sterilized food product will now be described. At the beginning (box 52), the method includes sterilizing (box 54) an intermodal container comprising a rigid shell having a belt An elongated shape with relatively closed ends. Sterilizing may include sterilizing the interior of the intermodal container using at least one of water vapor and a chemical sterilant.

In some embodiments, the intermodal container may be of the conventional type described above and offered by Hawaii Intermodal; however, in other embodiments, the intermodal container may be of the advantageous type described below. The intermodal container may include at least one support frame assembly supporting the rigid shell and configured to allow rotation between a generally horizontal orientation and a generally vertical orientation.

The generally upright orientation may be at an angle greater than 40° from horizontal, and the generally horizontal orientation may be at an angle less than 40° from horizontal. Of course, it is often possible that an intermodal container is transported in an almost exactly horizontal orientation, and that the intermodal container is emptied in a fully upright or vertical orientation, as will be understood by those skilled in the art.

The method also includes aseptically filling the intermodal container with the sterilized food product at box 56 . At block 58, the method further includes transporting the filled intermodal container via at least one of rail, truck, and ship in a substantially horizontal orientation while maintaining the sterilized food product under aseptic conditions. At the desired emptying destination, the method includes rotating the intermodal container to a generally upright orientation at block 60 and emptying the sterilized food product from the discharge port before stopping at block 64 (block 62) . The method advantageously allows for the efficient transportation of large quantities of sterilized food products, and the intermodal container can be emptied with the advantage of gravity-based emptying. Emptying can also be performed aseptically, as will be understood by those skilled in the art.

This method is particularly advantageous for such emptying when the sterilized food product comprises a viscous sterilized food product such as like citrus pulp or other food product having an absolute viscosity greater than 500 centipoise. Attempting to pump viscous food products out of conventional intermodal containers in a horizontal orientation in a conventional manner may take a relatively long time and/or leave an undesirably large amount of food product within the intermodal container, as would be determined by those skilled in the art. as understood by the personnel.

With additional reference to FIGS. 3A and 3B , rotation and evacuation are further described. Specifically, rotation is illustratively achieved by engaging the front support frame assembly 75b with a lifting device in the form of an overhead crane 90 comprising an elevated horizontal support member 91 carried by a movable crane crane. trolley 92, and hoisting cables 93a, 93b extending from the crane trolley. The intermodal container 70 may include suitable engagement fittings, such as eyelets or other openings to facilitate temporary attachment of the lift cables 93a, 93b. In some embodiments, suitable engagement fittings (not shown) may be positioned on rigid housing 71 . Of course in other embodiments, intermodal container 70 may be controlled and maneuvered using other types of mobile equipment.

Intermodal container 70 is illustratively lifted from truck bed 80 (FIG. 3A), rotated, and rear support frame assembly 75a is placed on emptying station 82 (FIG. 3B). Pump 83 is typically coupled in fluid communication with discharge port 77 via a sterile valve (not shown) secured to rigid housing 71 at the discharge port. In other embodiments, gravity feed alone is sufficient, and thus the pump 83 is not required, or placed immediately below the rigid housing 71 .

In a typical embodiment, an intermodal container may have a capacity of greater than 10,000 liters, such as typically about 24,000 liters. Unlike conventional intermodal container 30, as shown in FIG. In the middle part of 72a. The intermodal container 70 also illustratively includes a manhole cover 74, and the rigid shell 71 includes a dome-shaped front or front closed end 72b. Corner support posts 78 also illustratively extend from respective support frame assemblies 75a, 75b along the outside of rigid shell 71 to respective attachment areas.

As will be understood by those skilled in the art, the method may also include supplying sterile gas to maintain a positive pressure within the intermodal container 70, such as during transport or storage and also during emptying, since Positive pressure helps maintain sterile conditions suitable for sterile food products and can help empty the rigid housing 71 . Additionally, the method may further include maintaining at least one of a desired pressure and a desired temperature within the intermodal container 70 during transportation. Desired pressure and/or desired temperature can be recorded or transmitted wirelessly.

Referring now additionally to FIGS. 4 and 5 , another embodiment of an intermodal container 70 ′ will now be described. In this embodiment, the rear closed end 72a' of the rigid housing 71' having the discharge opening 77' therein has a conical shape, and the discharge opening is positioned at the apex of said conical shape. The conical shape may define an included angle α, for example greater than 45° and less than 90°. In other embodiments, the discharge port 77' may be offset from the axis of the cylindrical housing 71'. In these offset embodiments, it may not be necessary to rotate the intermodal container to a fully upright position, as will be understood by those skilled in the art.

The intermodal container 70' also illustratively includes a temperature sensor 101' and a pressure sensor 102' coupled to or positioned within the rigid shell 71'. A data logger in the form of a temperature and/or pressure monitor 103' is coupled to the sensors 101 ', 102'. The monitor 103' may include electronic circuitry carried, for example, by the rigid housing 71 ' or by the support frame assembly. The monitor 103' can be manually read as desired, or, as shown in the exemplary embodiment, the data stored by the monitor can be downloaded wirelessly via the wireless transceiver 104', as will be appreciated by those skilled in the art. as can be understood. This data can, for example, be overrun data or only periodically sampled data.

In embodiments where it is desired to maintain the sterilized food product at a temperature below room temperature, the refrigeration unit 105' may be coupled to the rigid housing 71'. The refrigeration unit 105' may be carried by one of a plurality of support frame assemblies or by the rigid housing 71 '.

Referring specifically to FIG. 5, the rigid shell 71' may include a stainless steel layer 106'. Additionally, an insulating layer 108' may surround the stainless steel layer 106'. The rigid housing 71' also illustratively includes an air inlet 90' to allow the flow of sterilizing gas to maintain a positive pressure within the rigid housing 71', such as during transport and/or evacuation. In other embodiments, the air intake 90' may alternatively be positioned in the front or within the front closed end 75b'.

The rigid housing 71' also has a fill opening 91' therein for the sterilized food product, and also has a man opening 92' therein. The air inlet 90' may include a suitable fitting (not shown) coupled thereto for external connection. The food product filling port 91' may also include a suitable fitting, not shown, coupled to the filling port. And the manhole 92' may have a suitable manhole opening associated therewith, not shown. Other configurations of manholes are also possible, as will be appreciated by those skilled in the art.

Another aspect relates to a method for aseptically filling an intermodal container 70'. Referring to the flowchart 120 of FIG. 6 , the filling method will be described. After starting (block 122), the method includes securing the sterile fitment to the filling port of the intermodal container (block 124). The aseptic fitting is not a conventional aseptic valve, as will be understood by those skilled in the art.

The intermodal container 70' may be of the type described above, although it is not necessary for these embodiments involving filling to provide the discharge outlet in the middle portion of the rear closed end. Of course, in some embodiments the spout arrangement, conical closed end, and sterile fitting as now described may be advantageously used in combination or all together.

The method also includes sterilizing the intermodal container (block 126 ), and at block 128 aseptically filling the sterilized intermodal container with the sterilized food product through the aseptic fitment. At block 130, the method also includes sealing the sterile fitment after aseptic filling. The filled intermodal container 70' is transported (box 132) before being emptied (box 134) and stopped at box 136.

As already explained, after the aseptic filling, the method may also include maintaining at least one of a desired pressure and a desired temperature within the intermodal container during transport. The method may include recording at least one of a desired pressure and a desired temperature, and wirelessly transmitting the data. Sterilization may be performed using at least one of water vapor and chemical sterilants. Thus, the method allows aseptically transporting larger quantities of sterilized food products without additional sterilization and/or pasteurization steps.

Turning additionally now to FIG. 7 , further features of the aseptic filling method, intermodal container 70 ′ and associated filling station 140 are now described. Aseptic filling is exemplarily performed using a movable aseptic filling head 142 which is part of an aseptic filling station 140 which also includes a A sterile food source 144 for the head. Typical aseptic filling stations for flexible bag containers, as described above in the background, rely on operators to manually attach the bag to the filling head. Such bag filling devices are not suitable for intermodal containers and related methods. Thus, the filling station 140 according to this aspect comprises a movable filling head 142 movable at least in the x-y plane. Movement in the z-direction is also advantageously provided. A frame (not shown) may mount the movable aseptic filling head 142 and various associated positioning actuators (not shown), as will be understood by those skilled in the art.

Of course, the relatively large intermodal container 70' will typically be held in a fixed position during the aseptic filling process, such as when positioned on the bed of a truck. Filling thus involves aligning the movable aseptic filling head 142 relative to the intermodal container 70', since the intermodal container is stationary.

To facilitate alignment of the movable aseptic filling head 142 relative to the rigid housing 70' and aseptic fitting 150', the filling head may have at least one sensor 145 coupled thereto. The sensor 145 may operate based on at least one of optical, mechanical and electrical sensing. For example, sensor 145 may be a video camera. Of course other configurations and types of sensors may be used. Additionally, intermodal container 70' may include at least one alignment feature 146' adjacent to aseptic fitment 150'. For example, the alignment features 146' may include optically visible marking patterns, mechanically sensing ridges or patterns, or capacitive or inductive components suitable for electrical sensing, as will be appreciated by those skilled in the art. understand that. In some embodiments, no alignment features may be required on the rigid housing 70', such as optical sensing like using a camera.

The truck-loaded intermodal container 70' can be positioned within the possible range of motion of the movable filling head 142, and thereafter the movable filling head 142 can guide itself into precise engagement with the sterile fitting 150', or Guidance can be carried out by means of the operator. Of course in other embodiments, a transport vehicle other than a truck may be used to carry the intermodal container 70', as will be appreciated by those skilled in the art.

In some embodiments, the aseptic fitment 150' comprises a membrane-type aseptic fitment, and the movable aseptic filling head 142 is compatible with the membrane-type aseptic fitment. In other embodiments, the aseptic fitment 150' comprises a cap-type aseptic fitment, and the movable aseptic filling head 142 is compatible with the cap-type aseptic fitment. The method may further include supplying a sterile gas to maintain a positive pressure within the intermodal container 70' during the aseptic filling process. Sterile gas may be introduced through gas inlet 90' (FIG. 5).

Sterilized food source 144 may include a viscous sterilized food product having an absolute viscosity greater than 500 centipoise, such as sterilized citrus pulp. In other embodiments, the sterilized food product may comprise sterilized fruit or vegetable juice or other fluid food product, as will be understood by those skilled in the art.

Other aspects and features of the intermodal container 70' have been described with respect to shipping and emptying, and these same features also facilitate aseptic filling and shipping. For example, after aseptic filling by aseptic fitting 150', optional refrigeration, insulation and data logging may also be used, as will be understood by those skilled in the art.

Traditional filling methods typically require re-sterilization of feed tubes and hoses during each filling cycle. These methods are time consuming and subject to possible contamination.

Aseptic filling heads suitable for bag containers are known in the prior art. For example, US Patent Application Nos. 4,445,550 and 4,805,378 respectively disclose such aseptic filling heads, and each patent is incorporated herein by reference in its entirety.

Aseptic fittings with frangible membranes (rupture discs) are described in US Patent 4,494,363, incorporated herein by reference in its entirety, and assigned to FranRica Mfg. Inc. Fittings of this type are currently manufactured by companies such as Scholle Corporation of North Lake, IL, under model designations 1700 and 5100. Aseptic fittings with plastic caps are disclosed in US Patent Application Nos. 4,355,742 and 4,120,134, each of which is incorporated herein by reference in its entirety. Scholle Corporation also manufactures cap fittings under model designations 800X, 800L, and 2600. Other prior art packaging materials and filling equipment are disclosed in Application Nos. 3514919; 2930170; 3340671; 3356510; 3427646; 4137930; and 4201208, each of which is incorporated herein by reference in its entirety.

Bag-in-box (300 gallon) containers and other packaging materials as described above are currently being filled by an aseptic filling head. However, these are flexible bag containers with capacity limitations, and they are also not pressurized. In these systems, the filling head is fixed in the x-y plane and the fitting of the flexible container moves to cooperate with the filling head. Filling is currently done on top of tank trucks and intermodal containers through common fill/drain valves. Unfortunately, valves and filling hoses need to be sterilized between each tank truck. The methods, intermodal containers and filling stations described herein overcome these and other deficiencies of prior art methods.

For film-type fittings, the movable aseptic filling head 142 is aligned with and seals against the aseptic filling fitting 150' during filling. The sterile fittings and the outer surfaces of the filling head are then sterilized by steam or chemical sterilizers. The frangible film is broken by the filling head and the sterile food product is introduced into the intermodal container 70'. The sterile cap is sealed over the fitting while still under sterile conditions, and the sterile filling head 142 is removed from the sterile fitting 150'. For cap fittings, the cap is first removed and then replaced after filling.

Other aspects of the embodiments described herein will now be described with additional reference to FIGS. 8 and 9 . The intermodal container 180 is fitted with a manhole cover 189 comprising various fittings. These fittings include a membrane aseptic fitting 200 and a pair of alignment rods 194 for alignment with the aseptic filling head 190 . Other fittings (not shown) may include fittings for cleaning, tank access, and introduction of sterile gases, as will be understood by those skilled in the art.

Aseptic filling head 190 includes a movable frame 191 that allows movement of aseptic filling chamber 192 in the x-y plane for alignment with aseptic fitting 200 . Aseptic filling chamber 192 includes alignment features which are alignment rod receiving slots that cooperate with alignment rods 194 for aligning filling head 190 relative to manhole cover 189 and thus relative to said sterile fitting 200 193 forms. Contacts and/or proximity sensors 195 are also provided for sensing when filling chamber 192 is in the correct upright position relative to intermodal container 180 . Filling chamber 192 may be one of many types available in the industry, such as those manufactured by JBT Corporation or Scholle Corporation. The aseptic filling head 190 also illustratively includes an actuator 196 for upright movement (along the z-axis) and a flexible hose 197 for transporting the food product.

Other components of the intermodal container 180 include a product discharge valve 184, and a gas line 186 having an inlet 187 for introducing sterile gas into the container through a sterile gas filter cartridge 185, as shown in FIG. . Upright filling pipe 188 is connected to the filling port of intermodal container 180 . The optional filling tube 188 allows certain liquids to be filled to the bottom of the intermodal container 180 in order to minimize or reduce splashing or foaming during the filling operation.

With additional reference now to FIGS. 10-14 , the film aseptic filling fitting 200 is further described. Fitting 200 includes a sterile fitting body 201 , a sealing disc 202 , and a screw cap 203 . Fitting body 201 is preferably molded from a suitable plastic material such as high density polyethylene. Fitting body 201 receives a frangible membrane or membrane 204 to extend through filling opening 205 . Membrane 204 has sufficient strength to withstand a pressure of, for example, 15-30 pounds that the membrane may be exposed to during sterilization of lower neck opening 206 installed on intermodal container 180 .

The fitting body 201 also includes a clamping flange 207 for receiving the clamping jaws of the filling head 190, a threaded neck 208 adapted to receive the screw cap 203, and a collar 211 for clamping to the receiving tank (FIG. 13 ) on the ramp clamping shoulder 210. The beveled clamping shoulder 210 is, for example, of the style known as an I-line fitting. Other aseptic connections such as DIN 11864-2 aseptic flanged unions or DIN 11-864-1 aseptic threaded unions may also be used to install filling fitting 200 to the intermodal container.

Another embodiment of a film-type sterile fitting 200' is shown in Figure 11 and includes a fitting body 201' molded from a suitable plastic material and a separate beveled gripping shoulder 210', preferably made of stainless steel . These two parts are bonded together by melting the molded plastic fitting body 201, or by using a suitable adhesive.

Another alternative embodiment of a film-type sterile fitting 200" will now be described with particular reference to Figures 12A and 12B. In this embodiment, the filling fitting 200" comprises a canister molded from a suitable plastic material. Fitting body 201" and a separate two-piece beveled clamping shoulder 210", preferably made of stainless steel. The two-piece bevel clamping shoulder 210″ includes a left-hand shoulder portion 210a″ and a right-hand shoulder portion 210b″, which during assembly to the intermodal container 180, the left-hand shoulder portion 210a″ and the right-hand shoulder portion 210b "Assembled to accessory body 201". The fitting body 201" also includes a lower shoulder 212" for sealing against the gasket 215 during assembly onto the intermodal container 180 (Fig. 13).

Membrane aseptic fitment 200 when assembled to intermodal container 180 is further described with more particular reference to FIG. 13 . Receiving ferrule 211 is preferably a stainless steel ferrule, such as a female I-wire ferrule welded to manhole cover 189 . A gasket 215 of suitable material such as Viton is positioned between the fitting body 201 and the mating ferrule 211 and is sealed in place by use of a clamp 214 such as an I-wire clamp. The interior space 216 within the neck of the receiving collar 211, the gasket 215 and the lower filling opening 206 of the fitting body 201 along with the interior of the intermodal container 180 can all be sterilized by steam or chemical sterilants, as will be described in the art. within the understanding of those skilled in the art. The upper filling opening 205 of the fitting 200 along with the upper surface of the membrane 205 is sterilized by the aseptic filling head 190 before the membrane 204 is ruptured during filling.

As best shown in Figure 14, after the filling operation is complete, the membrane 204 has ruptured and the sealing disk 202 has been sealed and secured by the cap 203 to the fitting body 201 . The sealing disc 202 is preferably formed from a multilayer material comprising layers of low density polyethylene and a layer of aluminum foil bonded together by an adhesive. After filling, the disc 202 is sealed to the fitting body 201, eg by heat.

Turning now to FIGS. 15-18 , a cap-type aseptic fitment 220 suitable for use on intermodal container 180 is now described. The sterile fitting 220 includes a fitting body 221 and a sealing cap 222 . Fitting body 221 is preferably molded from a suitable plastic material such as high density polyethylene. The fitting body 221 includes an upper clamping flange 223 and a lower clamping flange 224 for receiving the clamping jaws of the filling head, and a ramped clamping shoulder portion 225 for clamping onto the receiving tank collar 211 . The ramped clamping shoulder portion 225 is, for example, of the style known as an L-shaped wire fitting. The sealing cover 222 includes an upper contact ring 226 and a lower contact ring 227 for sealing with the fitting body 221 . Prior to filling, for example as shown in Figure 15, the cap 222 is partially pushed into the fitting body 221 such that the lower contact ring 227 is in sealing contact with a corresponding recess in the fitting body.

Another embodiment of a cap-shaped sterile fitting 220' is shown in FIG. 16 . In this embodiment, for example, the filling fitting 220' comprises a filling fitting body 221' molded from a suitable plastics material, and a separate beveled clamping shoulder at the base of the body, preferably of stainless steel Section 225'. The two parts 221', 225' are bonded together by melt molding the plastic fitting body 221' or by using a suitable adhesive.

Another alternative embodiment of a cap-type aseptic filling fitting 220" is shown in Figures 17A and 17B. In this embodiment, the fitting 220" comprises a filling fitting molded from a suitable plastic material Main body 221" and a separate two-piece beveled clamping shoulder 225", preferably made of stainless steel. The two-piece bevel clamping shoulder 225″ includes a left-hand shoulder portion 225a″ and a right-hand shoulder portion 225b″, which during assembly to the intermodal container 180, the left-hand shoulder portion 225a″ and the right-hand shoulder portion 225b "Assembled to fitting body 221". The fitting body 221" also includes a lower shoulder 229" for sealing against the gasket 215 during assembly onto the intermodal container 180 (Fig. 18).

As shown in FIG. 18 , cap-type aseptic fitment 220 is assembled to intermodal container 180 at receiving collar 211 connected to manhole cover 189 of intermodal container 180 . Receiving ferrule 211 is preferably a stainless steel ferrule, such as a female I-wire ferrule welded to manhole cover 189 . A gasket 215 of suitable material, such as Viton, is positioned between the lower end of the fitting body 221 and the mating receiving ferrule 211, and is sealed in place by use of a clamp 214, such as an I-wire clamp. As will be understood by those skilled in the art, the inner neck region 230 of the receiving collar 211, the gasket 215, and the lower filling opening 231 and inner cap cavity 232 of the fitting body 221 along with the inner portion of the intermodal container 180 All can be sterilized by steam or chemical sterilizers. The outer surface of cap 222 is sterilized by a sterile filling head before the cap is removed during filling.

During the container sterilization process or aseptic filling process, the only surface of the non-sterile cap-type filling fitting 220 is in contact with the initial overlapping area extending along the length L between the cap 222 and the filling fitting body 221 Surface 235 (FIG. 15). To properly sterilize the surface 235, the filling fitment 220 may be sealed within a sealable package 236 (FIG. 19) of suitable material and exposed to gamma radiation. The entire cap aseptic filling fitting 220 is then kept clean and sterile until it is ready to be assembled onto the intermodal container 180 .

After filling and sealing one of the sterile fittings 200, 220, a hinged protective cover 236 may be positioned over the fitting to protect the fitting during transport, as shown in FIG. The hinged lid 236 may be locked to the container via a lock 237 as shown, or may be sealed with a tamper evident seal to prevent tampering during transport.

Referring now to the flowchart 250 of FIG. 21, another method for processing a sterilized food product will now be described. After initiation (block 252), the method includes sterilizing (block 254) an intermodal container, such as an intermodal container comprising a rigid shell having an elongated shape with front and rear closed ends and Discharge port in rear closed end. The intermodal container may also include front and rear support frame assemblies that support the rigid shell. In other words, the intermodal container may be of the type described herein. Sterilizing may include sterilizing the interior of the intermodal container with at least one of water vapor and a chemical sterilant. Other configurations of intermodal containers may also be used, as will be understood by those skilled in the art.

The method also includes aseptically filling the intermodal container with the sterilized food product at block 256 . At block 258, the method further includes transporting the filled intermodal container via a transport vehicle, such as at least one of rail, truck, and ship, while maintaining the sterilized food product under aseptic conditions.

At the desired emptying destination or station, the method includes moving the intermodal container to an inclination angle of at least 8 degrees from horizontal at block 260 . For example, in some embodiments, this is accomplished by pushing the front support frame assembly upward to rotate the intermodal container from horizontal to an inclination angle of at least 8 degrees. Of course, in other embodiments, other methods may be used to rotate or move the intermodal container to an inclination angle of at least 8 degrees from horizontal, such as engaging the intermodal container and/or its support frame assembly with a lifting device. The method also includes emptying the sterilized food product from the discharge port before stopping at block 264 (block 262).

In some embodiments, a pump may be used in addition to gravity. Additionally, the method may include supplying a sterile gas to maintain a positive pressure, eg, 5 to 20 psi, within the intermodal container at least during emptying to provide additional pressure to assist emptying. Attempting to simply pump such viscous food products out of the intermodal container in a horizontal orientation may take a relatively long time and/or leave an undesirably large amount of food product within the intermodal container, as will be appreciated by those skilled in the art. understand that.

The method advantageously allows for efficient transport of large quantities of sterilized food products, and intermodal containers can be emptied taking advantage of gravity-based or gravity-assisted emptying. The method is particularly advantageous for such emptying when the sterilized food product comprises a viscous sterilized food product, such as like citrus pulp or other food product having an absolute viscosity greater than 500 centipoise. Emptying can also be performed aseptically, as will be understood by those skilled in the art.

The method may include maintaining at least one of a desired pressure and a desired temperature within the intermodal container during transportation. Additionally, the method may include at least one of recording and wirelessly transmitting at least one of the desired pressure and the desired temperature.

In some embodiments, the angle of inclination may be at least 18 degrees from horizontal, and in other embodiments may be at least 30 degrees from horizontal. It has been determined that at an angle of 8 degrees, while maintaining a pressure of 15 psi (pounds per square inch) inside the intermodal container, about 1.6% of the sterilized food product in the form of citrus pulp remains within the intermodal container. At an angle of 18 degrees, approximately 0.5% of the sterilized food product (citrus pulp) remained inside the intermodal container at the same pressure. Either of these angles may be acceptable depending on the particular requirements of the user, as will be understood by those skilled in the art. In other embodiments, an angle of at least 30 degrees may also be used and is readily available.

With additional reference to FIG. 22 , one embodiment of a system 290 for urging forward support assembly 275b upward to rotate and empty intermodal container 270 is further described. In this embodiment, a transport vehicle in the form of a truck 291 including a truck bed 280 carrying the intermodal container 270 is rotated by causing the truck to travel on an upwardly inclined ramp 292 . The ramp 292 has a slope angle β of at least 8 degrees, or at least 18 degrees in other embodiments, or at least 30 degrees in still other embodiments.

The intermodal container 270 may have a capacity greater than 10,000 liters and have a discharge opening 277 in a lower portion of the intermodal container's rear closed end 272a opposite the front closed end 272b. The intermodal container 270 also has a front support frame assembly 275b and a rear support frame assembly 275a. The intermodal container 270 also illustratively includes a rigid shell 271 and a plurality of corner support posts 278 extending along the outside of the rigid shell from respective support frame assemblies 275a, 275b to respective attachment areas. A manhole 274 may also be provided for accessing the interior of the housing 271 .

During evacuation, sterile gas may be supplied to the interior of the rigid housing 271 from a sterile gas source 294 . A first outlet hose 285 is also illustratively coupled between the discharge port 277 and the pump 283 . The sterile food product is then propelled by the pump 283 through the second outlet hose 284 coupled thereto.

Referring now to FIG. 23, another embodiment of a system 290' for evacuation is further described. In this embodiment, a transport vehicle in the form of a truck 291' including a truck bed 280' carrying the intermodal container 270 pushes the front support frame assembly 272b' upward by driving the truck onto a hydraulically raised platform 292'. Hydraulic lift 293' travels one or more retractable pistons 294' to rotate platform 292' and thus truck 291' and attached intermodal container 270' through an inclination angle of at least 8 degrees, or at least 18 degrees, or at least 30 degrees β, as above. In other words, in this embodiment, a lift is used to raise the truck 291 ' relative to the rear of the truck, thereby pushing the front support frame 272b' and rotating the intermodal container 270'. Those other elements of system 290' not specifically described are the same as those described above with reference to FIG. 22 .

Many modifications and other embodiments of the invention will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, the methods and structures disclosed herein for transporting containers are also applicable to on-road tank cars, and/or rail vehicles, as will be understood by those skilled in the art. Therefore, it is to be understood that the inventions are not to be limited to the particular embodiments disclosed and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims (15)

1. one kind for processing and transport viscosity in intermodal container, sterilized food The method of product, this food product be have more than 500 centipoise absolute viscosities citrus pulp or Person's vegetable juice, described method includes:

This intermodal container carries out sterilizing, and described intermodal container includes stiff case and props up The front support frame assembly of support stiff case and back support frame assembly, described rigidity Housing has with rear closure end and the elongated shape of closed front end and seals at rear portion Aseptic outlet in closed end portion, it is sufficient to allow this intermodal container by truck, railway or ship Oceangoing ship transports, and allows this intermodal container to overlie one another；

With sterilized have more than the citrus pulp of 500 centipoise absolute viscosities or vegetable juice without The filling intermodal container of bacterium；

Via haulage vehicle or the Shipping intermodal container after filling, keep sterilized simultaneously Citrus pulp or vegetable juice be under aseptic condition；And

At an emptying website, push away front support frame assembly upward, in order to by through transport Container rotates to into the inclination angle of at least 8 degree from horizontal direction, and from aseptic outlet row The empty sterilized citrus pulp from intermodal container or vegetable juice.

Method the most according to claim 1, it is characterised in that push away upward and include so that fortune Defeated vehicle is advanced with acclivitous inclined-plane.

Method the most according to claim 1, it is characterised in that push away upward and include so that fortune The front portion of defeated vehicle raises relative to the rear portion of haulage vehicle.

4., according to the method one of claim 1-3 Suo Shu, farther include at least emptying Journey supplies sterilizing gas to keep the normal pressure in intermodal container.

5., according to the method one of claim 1-3 Suo Shu, further include in evacuation procedure Use the pump being connected to outlet.

6. according to the method one of claim 1-3 Suo Shu, it is characterised in that inclination angle and level Direction at least becomes 18 degree.

7. according to the method one of claim 1-3 Suo Shu, it is characterised in that inclination angle and level Direction becomes at least 30 degree.

8. according to the method one of claim 1-3 Suo Shu, it is characterised in that sterilizing includes using In water vapour and chemosterilant at least one carry out sterilizing.

9. the side of the sterilized food product for processing and transport in intermodal container Method, this food product includes having the citrus pulp more than 500 centipoise absolute viscosities or vegetables Juice, the method includes:

It is filled with sterilized having more than 500 centipoise absolute viscosities via transport vehicle transports This intermodal container of citrus pulp or vegetable juice, keep simultaneously sterilized citrus pulp or Person's vegetable juice is under aseptic condition, and intermodal container includes stiff case and rigidity of support shell The front support frame assembly of body and back support frame assembly, described stiff case has With rear closure end and the elongated shape of closed front end and in rear closure end Aseptic outlet, it is sufficient to allow this intermodal container by truck, railway or Shipping, And allow this intermodal container to overlie one another；And

At an emptying website, push away front support frame assembly upward, in order to by through transport Container rotates to into the inclination angle of at least 8 degree from horizontal direction, and from this intermodal container Aseptic outlet empties sterilized citrus pulp or vegetable juice.

Method the most according to claim 9, it is characterised in that push away upward include so that Haulage vehicle is advanced with acclivitous inclined-plane.

11. methods according to claim 9, it is characterised in that push away upward include so that The front portion of haulage vehicle raises relative to the rear portion of haulage vehicle.

12. according to the method one of claim 9-11 Suo Shu, farther includes at least in emptying During supply sterilizing gas to keep the normal pressure in intermodal container.

13., according to the method one of claim 9-11 Suo Shu, further include at evacuation procedure Middle use is connected to the pump of outlet.

14. according to the method one of claim 9-11 Suo Shu, it is characterised in that inclination angle and water Square at least becoming 18 degree.

15. according to the method one of claim 9-11 Suo Shu, it is characterised in that inclination angle and water Square to become at least 30 degree.