WO2025038612A1

WO2025038612A1 - Improved bottlewash system

Info

Publication number: WO2025038612A1
Application number: PCT/US2024/042063
Authority: WO
Inventors: Nils DEECKE
Original assignee: The Coca-Cola Company
Priority date: 2023-08-14
Filing date: 2024-08-13
Publication date: 2025-02-20
Also published as: WO2025038612A9

Abstract

A water and energy reuse system for a bottle washing system may include a post-caustic bottle rinsing area with a plurality of bottle rinsing stations arranged in series, each of the bottle rinsing stations comprising a plurality of bottle rinsing nozzles and a reservoir adapted to collect rinse water. The system may include a rinse water heat exchanger with a rinse water inlet configured to be coupled to the reservoir of a bottle rinsing station to receive heated rinse water and a rinse water outlet configured to supply a source of cooled rinse water. The system may include a water treatment system with an inlet configured to be coupled to receive rinse water from the reservoir of one of the rinsing stations and an outlet configured to supply treated water to one or more of the bottle rinsing nozzles of the last of the plurality of bottle rinsing stations.

Description

IMPROVED BOTTLEWASH SYSTEM

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63/519,294, filed August 14, 2023, which is incorporated herein by reference in its entirety

BACKGROUND

[0002] Rather than single use packaging, some beverages are being bottled in reusable, returnable, and/or refillable containers (e.g., glass or durable plastic). The advantages of such a bottling system are clear - the bottles are cleaned are reused multiple times thereby reducing costs for creating new bottles. Traditional bottle washing systems can use large amounts of water and energy.

SUMMARY

[0003] Various implementations include a water and energy reuse system for a bottle washing system, the bottle washing system including a post-caustic bottle rinsing area with a plurality of bottle rinsing stations arranged in a series, each of the bottle rinsing stations including a plurality of bottle rinsing nozzles and a reservoir adapted to collect rinse water dispensed from the plurality of bottle rinsing nozzles. The water and energy reuse system includes a rinse water heat exchanger with a rinse water inlet configured to be coupled to the reservoir of one of the bottle rinsing stations to receive heated rinse water and a rinse water outlet configured to supply a source of cooled rinse water and a water treatment system with an inlet configured to be coupled to receive rinse water from the reservoir of one of the plurality of bottle rinsing stations and an outlet configured to be coupled to and supply treated water to one or more of the bottle rinsing nozzles of the last of the plurality of bottle rinsing stations in the series.

[0004] In some implementations, the inlet of the rinse water heat exchanger is configured to be coupled to the reservoir of the first of the plurality of bottle rinsing stations in the series. [0005] In some implementations, the water treatment system includes one or more of an ultrafiltration membrane, a nanofiltration membrane, or reverse osmosis filtration membrane. [0006] In some implementations, the water treatment system is configured to produce the treated water with one or more of pH correction, particle removal, or sodium removal. [0007] In some implementations, the rinse water heat exchanger further comprises a heat transfer fluid inlet configured to receive a heat transfer fluid and a heat transfer fluid outlet configured to supply the heat transfer fluid heated by the heated rinse water.

[0008] In some implementations, the rinse water outlet of the rinse water heat exchanger is configured to be coupled to the inlet of the water treatment system to supply the source of cooled rinse water to the water treatment system.

[0009] In some implementations, the rinse water outlet of the rinse water heat exchanger is configured to be coupled to the reservoir of an intermediate one of the plurality of hottie rinsing stations in the series.

[0010] In some implementations, the inlet of the water treatment system is configured to be coupled to the reservoir of the last of the plurality of bottle rinsing stations in the series.

[0011] In some implementations, the heat transfer fluid inlet and the heat transfer fluid outlet are configured to be coupled to an external system for heat exchange therebetween.

[0012] In some implementations, the water and energy reuse system further includes a heat pump coupled to the rinse water heat exchanger for heat exchange therebetween and a caustic heat exchanger coupled to the heat pump for heat exchange therebetween. The caustic heat exchanger includes a caustic inlet configured to be coupled to a caustic reservoir of bottle washing system and a caustic outlet configured to supply a source of heated caustic to the caustic reservoir.

[0013] In some implementations, the heat pump comprises an evaporator, wherein the evaporator includes a heat transfer fluid inlet and a heat transfer fluid outlet of the rinse water heat exchanger.

[0014] In some implementations, the caustic heat exchanger further comprises a second heat transfer fluid inlet configured to receive a second heat transfer fluid and a second heat transfer fluid outlet configured to supply the second heat transfer fluid heated by the heat pump and the heat transfer fluid.

[0015] In some implementations, the heat pump comprises a condenser, wherein the condenser includes the second heat transfer fluid inlet and the second heat transfer fluid outlet of the caustic heat exchanger.

[0016] Various other implementations include a water and energy reuse method for a bottle washing system. The bottle washing system includes a post-caustic bottle rinsing area with a plurality of bottle rinsing stations arranged in a series, each of the bottle rinsing stations comprising a plurality of bottle rinsing nozzles and a reservoir adapted to collect rinse water dispensed from the plurality of bottle rinsing nozzles. The water and energy reuse method includes receiving heated rinse water from the reservoir of one of the bottle rinsing stations at a rinse water inlet of a rinse water heat exchanger; supplying a source of cooled rinse water from a rinse water outlet of the rinse water heat exchanger; receiving rinse water from the reservoir of one of the plurality of bottle rinsing stations at an inlet of a water treatment system; and supplying treated water from an outlet of the water treatment system to one or more of the bottle rinsing nozzles of the last of the plurality of bottle rinsing station in the series.

[0017] In some implementations, the water and energy reuse method further includes receiving a heat transfer fluid at a heat transfer fluid inlet of the rinse water heat exchanger; and supplying the heat transfer fluid heated by the heated rinse water to a heat transfer fluid outlet of the rinse water heat exchanger.

[0018] In some implementations, the water and energy reuse method further includes supplying the source of cooled rinse water to the water treatment system from the rinse water outlet of the rinse water heat exchanger.

[0019] In some implementations, the water and energy reuse method further includes supplying the source of cooled rinse water to the reservoir of an intermediate one of the plurality of bottle rinsing stations in the series from the rinse water outlet of the rinse water heat exchanger.

[0020] In some implementations, the receiving rinse water at the inlet of a water treatment system includes receiving rinse water from the reservoir of the last of the plurality of bottle rinsing stations in the series.

[0021] In some implementations, the water and energy reuse method further includes supplying the heated rinse water from the heat transfer fluid outlet of the rinse water heat exchanger to an external system for heat exchange; and receiving the heat transfer fluid at the heat transfer fluid inlet of the rinse water heat exchanger from the external system.

[0022] In some implementations, the water and energy reuse method further includes exchanging heat between a heat pump and the rinse water heat exchanger; receiving caustic from a caustic reservoir of bottle washing system at a caustic inlet of a caustic heat exchanger coupled to the heat pump for heat exchange therebetween; and supplying a source of heated caustic to the caustic reservoir from a caustic outlet of the caustic heat exchanger.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Fig. 1 shows a diagram of a representative bottle washing system, according to one implementation. [0024] Fig. 2 illustrates an example bottle washing system, according to one implementation.

[0025] Fig. 3 illustrates an example bottle washing system, according to one implementation.

[0026] Fig. 4 illustrates an example bottle washing system, according to one implementation.

[0027] Fig. 5 illustrates an example bottle washing system, according to one implementation.

[0028] Fig. 6 illustrates an example bottle washing system, according to one implementation.

[0029] Fig. 7 shows a flowchart for a method of use for a bottle washing system, according to one implementation.

DETAILED DESCRIPTION

[0030] It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents. Use of the phrase “and/or” indicates that any one or any combination of a list of options can be used. For example, “A”, “B”, and/or “C” means “A”, or “B”, or “C”, or “A and B”, or “A and C”, or “A and B and C”.

[0031] A need exists for reducing energy and water consumption of bottle washing systems. Water consumption in bottle washing systems is driven in part by the post-caustic area of the bottle washer. The post-caustic area both cools the bottles and rinses the caustic solution carried over from the caustic baths. The rinse water can be internally reused for other processes (e.g., pre-jetting, label removal, etc.) before being discharged as wastewater. Those other processes require only a fraction of the water used in the whole system.

[0032] In this disclosure, the other processes are supplied with only the minimum water required for operation, while the rest of the water used in the post-caustic area is collected, cooled, cleaned, and reused. Cooling is accomplished by a heat exchanger and, in some implementations, an electric heat pump to supply thermal energy to some other process (e.g., the caustic baths). The result is reduced energy consumption of the overall system.

[0033] The cooled water can be treated to remove particles, correct pH, and to remove sodium, depending on the use-case and the specific process involved. The treatment may also include nano- or ultrafiltration.

[0034] A water and energy reuse system as described in this disclosure may be mounted on a skid as an off-the-shelf solution or a retrofit for an existing bottle washer. In other implementations, the water and energy reuse system is integrated into a new bottle washer in line or as an add-on attachment. By way of several examples and descriptions of the provided figures, one will understand the devices, systems, and methods disclosed herein.

Representative Diagram and Description

[0035] Fig. 1 provides a representative diagram for a system 100 which includes a water and energy reuse system 102 and a bottle washing system 104. The bottle washing system 104 is configured to receive bottles 106 (e.g., glass bottles or durable plastic bottles for reuse in a beverage bottling process) which are carried along a track or conveyor, roughly illustrated as lines in the flowchart of Fig. 1 . While bottles 106 are used in this example, any type of reusable packaging is contemplated by this disclosure. The bottle washing system 104 includes optional pre-rinse stations. An overview of the bottle pre-processing and cleaning are provided here for context, though additional or fewer stations or other modifications are contemplated by this disclosure. In an example, the bottle washing system 104 includes label removal station 108 to remove label residue from bottles 106 with high pressure waterjets. [0036] Next, a caustic bath 110 is provided for treating and cleaning the bottles 106 (e.g., in caustic soda (NaOH) solution). The bottles 106 can be submerged into the caustic bath 110 as they travel along the track. In some implementations, the caustic bath 1 10 may include heated caustic solution (e.g., at 65-75° C). While caustic treatments are common in bottle washing processes generally, the caustic bath 110 is optional because any cleaning process may be provided in the system 100. In some implementations, the caustic bath 110 may alternately be referred to as a cleaning station 110.

[0037] The bottle washing system 104 next includes a post-caustic bottle rinsing area 112. The post-caustic bottle rinsing area 112 has the dual purpose of (i) rinsing off the caustic solution or other cleaning solutions from the bottles 106 and (ii) cooling the bottles 106 in a controlled manner to a target temperature or less (e.g., 40 C or less). The post-caustic bottle rinsing area 112 rinses the bottles 106 progressively until all caustic or cleaning solution is removed and only potable, clean, filtered, and/or fresh drinking water is in contact with the bottles 106. Additionally, the post-caustic bottle rinsing area 112 reduces the temperature of the bottles 106 in a controlled progression starting from a higher temperature when exiting the caustic bath 110 or other high temperature cleaning device. Rather than shock the bottles 106 with a cool temperature immediately (which may result in cracking, shattering, or otherwise undesirably stressing the bottles 106), the post-caustic bottle rinsing area 112 cools the bottles 106 in stages. By the end of the post-caustic bottle rinsing area 112, the bottles 106 have reached the target temperature (e.g., between 40 C and the temperature of a municipal water source). [0038] The post-caustic bottle rinsing area 112 includes a first bottle rinsing station 114a and a last bottle rinsing station 114b, collectively or singularly bottle rinsing stations 114. The bottles 106 enter each of the bottle rinsing stations 114 along the track to be rinsed with rinse water. In some implementations, the bottles 106 are inverted such that the open end of each bottle 106 faces downwards so that water may drain out of it. In the example shown in Fig. 1, there are two bottle rinsing stations 114, but a different number of the bottle rinsing stations 114 may be used (e.g., 1 3, 4, 5, 6, 8, 10, or more bottle rinsing stations).

[0039] The bottle rinsing stations 1 14 include a first nozzle array 1 16a, a last nozzle array 116b, a first reservoir 118a and a last reservoir 118b, collectively and singularly referred to as nozzle arrays 116 and reservoirs 118. The first nozzle array 116a has a plurality of bottle rinsing nozzles 120a- 120c and the last nozzle array 116b has a plurality of bottle rinsing nozzles 120d-120f, collectively and singularly referred to as bottle rinsing nozzles 120. The reservoirs 118 are adapted to collect rinse water dispensed from the bottle rinsing nozzles 120. In the example shown in Fig. 1, the nozzle arrays 116 each include three bottle rinsing nozzles 120, but in some implementations a different number of bottle rinsing nozzles 120 may be used (e.g., 1, 2, 4, 5, 8, 10, 15, or 20 nozzles per array). In some implementations, different ones of the nozzle arrays 116 may have different numbers of bottle rinsing nozzles 120.

[0040] One or more of the nozzles 120 may draw their rinse water from a municipal water source, which may supply water at around 16° C. For example a last nozzle (e.g., nozzle 120f in the example shown) or a last of the nozzle arrays 116 (e.g., nozzle array 116b in the example shown) may draw rinse water from the municipal water source. As water flows over the bottles 106 and drips into the reservoirs 118, thermal energy is transferred from the bottle to the rinse water and collected in the reservoirs 118. The post-caustic bottle rinsing area 112 is configured to rinse the bottles 106 progressively. Therefore, each bottle rinsing station 114 and respective nozzle arrays 116 and nozzles 120 are configured such that the water dispensed from nozzles 120 further downstream relative to the bottle track (e.g., nozzles 120d-120f) is a cooler temperature than the water dispensed from nozzles 120 further upstream relative to the bottle track (e.g., nozzles 120a- 120c). In some implementations, the first nozzles 120a, 120b, and 120c, of nozzle array 116a dispense rinse water at the highest temperature of the nozzles 120 (e.g., at a temperature slightly less than that of a caustic solution in caustic bath 110). In some implementations, the warmest of the collected rinse water may be in a reservoir 118 furthest upstream relative to the bottle track (e.g., reservoir 118a) which may be 55° C. In some implementations, the coolest water of the collected rinse water may be in a reservoir 118 furthest downstream relative to the bottle track (e.g., reservoir 118b) which may be 40° C.

[0041] In some implementations, the nozzles 120 may draw their rinse water from the reservoir 118 within a respective one of the bottle rinsing stations 114 or from an adjacent reservoir 118. The nozzles 120 may draw rinse water from the bottom of a reservoir 118, from the top of a reservoir 118, or from any location therebetween, depending on the required application.

[0042] In some implementations, each reservoir 1 18 is configured for a controlled overflow process. In the controlled overflow process, excess water in one reservoir (e.g., reservoir 118b) flows upstream relative to the direction of the bottle track and into the adjacent reservoir (e.g., reservoir 118a) which contains relatively warmer water compared to the downstream reservoir 118. In implementations where one or more nozzles 120 draws rinse water from a respective one of the bottle rinsing stations 114, the overflow process can cool down the collected rinse water in the reservoir 118.

[0043] In implementations where one or more nozzles 120 draws rinse water from an adjacent reservoir 118, and the adjacent reservoir 118 is downstream relative to the direction of the bottle track, the nozzles 120 may draw directly from the adjacent reservoir 118. In such an implementation, the adjacent reservoir 118 would contain rinse water which is cooler than that of the upstream reservoir 118, allowing for direct draw of rinse water into nozzles 120 of the upstream bottle rinsing station 114.

[0044] In implementations where one or more nozzles 120 draws rinse water from an adjacent reservoir 118, and the adjacent reservoir is upstream relative to the direction of the bottle track, an intermediate heat exchange process may occur before delivery to the nozzles 120. For example, in system 100, nozzle array 116b and nozzles 120d and 120e receive rinse water from reservoir 118a after a heat exchange process through the heat exchanger 124. This process cools the water so that the nozzles 120 further downstream relative to the bottle track can dispense rinse water at a temperature cooler than that of nozzles 120 further upstream relative to the bottle track.

[0045] Once the bottles 106 are cleaned and rinsed, traveling through each bottle rinsing station 114 of the bottle rinsing area 112, they pass towards a bottle outlet 122. The bottle outlet 122 may include a separate track or conveyor, or it may include a drying station.

[0046] Because the rinse water drips off the bottles, the water in the reservoirs 118 may not be pure drinking water, especially in the case of reservoir 118a closest to the caustic bath 110. The water in reservoir 118a contains a percentage of caustic or cleaning solution that has been rinsed from the bottles 106. Furthermore, the water in reservoir 118a is warmer than the water dispensed from nozzles 120 because some of the heat from the bottles 106 has been transferred to the used rinse water. Therefore, in the bottle rinsing area 112, reservoir 1 18a contains water that is both warmer and more caustic than that of reservoir 118b.

[0047] One advantage of system 100 and of the present disclosure is the water and energy reuse system 102 which utilizes the excess heat of the rinse water in one or more of the reservoirs 118. As shown, the water and energy reuse system 102 includes a rinse water heat exchanger, or simply “heat exchanger” 124. The heat exchanger 124 includes a warm water inlet 126 in fluid communication with the first reservoir 118a along warm rinse water line 128 such that the heat exchanger 124 can receive warm rinse water (e.g., rinse water from reservoir 118 at a temperature between 40° C and 55° C). In some implementations, the warm water inlet 126 is in fluid communication with a different reservoir 118 (e.g., an intermediate reservoir disposed in an additional bottle rinsing station between first and last bottle rinsing stations 114a and 114b). The heat exchanger 124 also includes a cold water outlet 130. Rinse water flowing out of the heat exchanger 124 at the cold water outlet 130 has been cooled relative to the rinse water that entered the heat exchanger 124. For example, rinse water flowing at the cold water outlet may be between 40° C and 22° C.

[0048] The cold water outlet 130 is in fluid communication with a water treatment system 134 along cold water line 132. The water treatment system 134 may include one or more of a pH-correction system, particle removal, sodium removal, reverse osmosis, nanofiltration, ultrafiltration, or any other common water treatment or filtration technique. The water treatment system 134 receives rinse water that has been cooled by the heat exchanger at a cold water inlet 136 and outputs treated water at the treated water output 138. The treated water travels from the treated water output 138 along the treated water line 140 and back into bottle rinsing station 114b. Specifically, the treated water supplies one or more of the nozzles 120. In some implementations, the treated water from treated water line 140 supplies an entire nozzle array 116. In other implementations, the treated water from treated water line 140 supplies all but the last nozzle in a nozzle array. In many cases, the last nozzle in line (e.g., nozzle 120f) is reserved for fresh water from a municipal supply. In this way, the rinse water from reservoir 118a is recirculated back into the system for use in one or more nozzles 120.

[0049] The water and energy reuse system 102 also includes a heat transfer fluid inlet 142 and a heat transfer fluid outlet 144 with corresponding heat transfer fluid lines 146 and 148. In one example, the heat transfer fluid flowing in heat transfer fluid lines 146 and 148 is a refrigerant. Heat transfer fluid line 146 brings heat transfer fluid (e.g., refrigerant) into the heat exchanger 124 to be in thermal communication with the rinse water entering the heat exchanger 124. Heat transfer fluid line 148 supplies the warmed heat transfer fluid from the heat exchanger 124 for use in another device.

[0050] Each heat transfer fluid line is in fluid communication with an external use device 150. The external use device 150 is meant to represent the various options for taking advantage of the heat removed from the rinse fluid and transferred by the heat exchanger 124. In one example, the external use device 150 is an electric heat pump configured to cycle the heat transfer fluid and transfer the heat for another purpose, such as heating another fluid. In some implementations, the heat pump includes an evaporator, a heat transfer fluid (e.g., refrigerant), heat transfer fluid inlets and outlets. In some implementations, the heat pump includes a condenser. In another example, the external use device 150 is a heating system configured to provide heating for a structure (e.g., an HVAC system in a building).

[0051] When the water and energy reuse system 102 is in use, warm rinse water from the first reservoir 118a (e.g., 55° C) flows along warm rinse water line 128 and into the heat exchanger 124 via water inlet 126. On the other side of the heat exchanger 124, heat transfer fluid flows along heat transfer fluid line 146 and enters the heat exchanger 124 and heat transfer fluid inlet 142. A heat exchange process occurs wherein warm rinse water and cool heat transfer fluid are in thermal communication to transfer heat from the rinse water to the heat transfer fluid. The warmed heat transfer fluid exits from heat transfer fluid outlet 144 and flows along heat transfer fluid line 148 towards the external use device 150. Meanwhile, cooled water (e.g., 22-40° C) exits the heat exchanger at cold water outlet 130 and flows along cold water line 132 towards the cold water inlet 136 of the water treatment system 134. After treatment in the water treatment system 134, treated and cooled water exits at treated water output 138 and flows along treated water line 140 and back into the last bottle rinsing station 114b. Specifically, the treated water supplies one or more of the nozzles 120 (e.g., nozzles 120d and 120e) of the last nozzle array 116b. Therefore, the rinse water is reused in the bottle washing system 104 while the water and energy reuse system 102 has utilized the heat from the rinse water for some other purpose. The result is a savings in both water and energy of the entire system 100.

[0052] The exemplary system described and illustrated in Fig. 1 may be implemented into a variety of bottle processing systems. The example systems herein described and illustrated in Figs. 2-6 include a variety of components and elements similar to that of system 100, but each system 200-600 represents an example implementation. Thus, system 100 is instructive upon, but not limiting or all-encompassing on the elements of each example system. Furthermore, Figs. 2-6 and the systems therein include a variety of components and elements not herein described but which may form other portions of that system working in conjunction with an example water and energy reuse system and an example bottle washing system. Systems 200-600 may recite example values (e.g., particular flow rates or temperatures). These example values are illustrative and provided as one example in the particular implementation. One will understand the variety and range of values that may be possible within each system 200-600.

Example system #1

[0053] One example of such an implemented system, system 200, is illustrated in Fig. 2. The system 200 includes a water and energy reuse system 202 and a bottle washing system 204. The system 200 represents a “3-loop circulation” system with a separated “treatment loop.” [0054] In system 200, bottles 206 travel along the track 205 for processing. First, the bottles encounter label removal station 208 removes label residue from bottles 206 with high pressure waterjets. Next, the bottles 206 are dipped into caustic treatment bath 210a. In system 200, two caustic treatment baths 210a and 210b are provided. The temperature of the first caustic treatment bath 210a is 65° C, while the temperature of the second caustic treatment bath 210b is 75° C. The caustic solution cleans and sanitizes the bottles 206.

[0055] The bottles 206 then move into the bottle washing system 204 which includes three bottle rinsing stations 214 (first bottle rinsing station 214a, second bottle rinsing station 214b, and third bottle rinsing station 214c). Each bottle rinsing station 214 includes a corresponding nozzle array 216 (first nozzle array 216a, second nozzle array 216b, and third nozzle array 216c), Each nozzle array 216 includes a plurality of nozzles 220. For example, first nozzle array 216a has three nozzles (unlabeled), second nozzle array 216b has three nozzles (unlabeled), and third nozzle array 216c has six nozzles (the first three of which are unlabeled). The last three nozzles 220 of the third nozzle array 216 are labeled as nozzle 220i, 220j, and 220k. Each bottle rinsing station also includes a reservoir 218 (first reservoir 218a, second reservoir 218b, and third reservoir 218c).

[0056] The bottles 206 are rinsed by each bottle rinsing station 214 on their way to the bottle outlet 222. The culminating nozzle 220k rinses the bottles 206 with fresh water (e.g., from a municipal water supply).

[0057] In system 200, the other nozzles 220 are supplied from a source other than the municipal water supply. For example, nozzles 220i and 220j are supplied by the water treatment system 234 which is in fluid communication with reservoir 218c. Reservoir 218c includes a flow path 232 from an outlet in the reservoir 218c in fluid communication with an inlet of the water treatment system 234. A flow path 240 allows water to flow from an outlet of the water treatment system 234 to an inlet of the nozzle array 216c, providing rinse water to be dispensed by nozzles 220i and 220j. In this way, the next-to-last rinse process includes treated rinse water that is reused. Any wastewater created in the treatment process is expelled along wastewater line 252. By treating and reusing rinse water, the system 200 reduces the amount of fresh water being supplied from the municipal source. For example, system 200 may only use 5 m³/hr compared to 13 m³/hr in a system without reusing rinse water.

[0058] The remaining nozzles of the third nozzle array 216c are supplied directly by water from reservoir 218c, creating a loop which fills up the reservoir 218c after a period of time. Reservoir 218c has an overflow path 217, allowing excess rinse water to drain into the reservoir 218b of the second bottle rinsing station 214b. The nozzles 220 of nozzle array 216b similarly draw rinse water from their corresponding reservoir 218b. Reservoir 218b also includes an overflow path 219 to the first reservoir 218a of the first bottle rinsing station 214a. Once again, the nozzles 220 in nozzle array 216a draw water from the first reservoir 218a.

[0059] Because of the progressive washing and cooling of the bottles 206, each reservoir 218 further upstream from another reservoir 218 relative the bottle track’s direction of travel contains warmer rinse water. For example, the rinse water in reservoir 218a, closest to the caustic baths 210, will be the warmest of the reservoirs 218 (e.g., 55°C). As the bottles 206 are rinsed from nozzles 220 of nozzle array 216a, excess water (now mixed with some caustic solution) drips down into reservoir 218a. This thermal transfer process cools the bottles 206 while warming the rinse water in reservoir 218a. However, the overflow path 219 brings relatively cooler water from reservoir 218b into reservoir 218a, cooling it slightly.

[0060] Reservoir 218b similarly warms up via the heat transfer process of receiving rinse water dripping from bottles 206. Reservoir 218b may have rinse water between 22° C and 55° C. Reservoir 218b then similarly cools down when receiving relatively cooler rinse water from reservoir 218c along overflow path 217. Reservoir 218b also cools down via the cool water line 254 following a heat exchange process with rinse water from reservoir 218c. This heat exchange process is described further below.

[0061] Reservoir 218c similarly warms up via the heat transfer process of receiving rinse water dripping from bottles 206. Reservoir 218c, however, receives cool rinse water not from an overflow path, but from the municipal water supply feeding the first nozzle 220k with fresh water at 16° C. [0062] Excess water from reservoir 218a can also be re-used along overflow line 258 (e.g., connected to a crate washing system to wash the crates in which the bottles are transported). Excess water from reservoir 218a can also be re-used along internal reuse line 264 for use in other systems and components of system 200 (e.g., in initial rinse cycles before the caustic baths).

[0063] As the bottles 206 are rinsed through each of the bottle rinsing stations 214, the caustic solution leftover from the caustic bath 210b is rinsed off of the bottle and into the corresponding reservoir 218. By the same process, heat from the bottle 206 is removed and transferred to the rinse water, which drains into the corresponding reservoir 218. As the bottles 206 progress towards the bottle outlet 222, they become progressively cleaner (e.g., less caustic solution and more fresh water in contact with the bottle surfaces) and progressively cooler. The inverse occurs with the rinse water - reservoir 218a contains the rinse water that is warmest and most caustic, while reservoir 218c, closest to the bottle outlet 222, contains the rinse water that is coolest and least caustic. The reservoir overflows and nozzle supply arrangements herein described take advantage of these differences to efficiently rinse the bottles, take advantage of excess water, and take advantage of excess heat energy.

[0064] The water and energy reuse system 202 of system 200 includes two heat exchangers 224a and 224b, each in fluid communication with a different portion of the system 200. For example, the reservoir 218a includes an additional fluid outlet in fluid communication with warm water line 228, and reservoir 218b includes an additional fluid inlet in fluid communication with cool water line 254, each connected to/forming a portion of the water and energy reuse system 202. The warm water line 228 and the cool water line 254 are each connected to and in fluid communication with the first heat exchanger 224a. In this way, excess warm water from reservoir 218a (e.g., at about 55° C) is cycled through the first heat exchanger 224a to take advantage of the excess heat for other uses. At the same time, the cooler water (e.g., 45° C) is repurposed in reservoir 218b of bottle rinsing station 214b so that cooler water can be dispensed from nozzles 220 in the nozzle array 216b, thereby reducing the amount of fresh water needed to maintain the bottle rinsing stations 214.

[0065] On the opposite side of the heat exchanger 224a is a heat transfer fluid loop 256 in thermal and mechanical communication with an electrical heat pump 250. The heat pump 250 receives electrical energy and circulates heat transfer fluid (e.g., refrigerant) through the heat transfer fluid loop 256 to facilitate heat exchange. For example, cooled heat transfer fluid leaves the heat pump 250 and enters the heat exchanger 224a where a heat exchange process occurs. Specifically, the warmed rinse water from reservoir 218a heats the cooled heat transfer fluid . Then, warmed heat transfer fluid leaves the heat exchanger along the heat transfer fluid loop 256 to return to the heat pump 250. Meanwhile, cooled rinse water leaves the heat exchanger 224a along cool water line 254 to return to the reservoir 218b.

[0066] In some implementations, the electrical heat pump 250 includes a compressor to compress and further heat the heated heat transfer fluid received from the heat exchanger 224a to a target temperature. Therefore, the electrical heat pump 250 performs less work on the heat transfer fluid to reach the target temperature because the heat transfer fluid has already been warmed by the heat exchanger 224a. In various implementations, the heat exchanger 224a is or includes an evaporator of the electrical heat pump 250.

[0067] To utilize the heat removed from the rinse water of reservoir 218a, a caustic heat exchanger, or “second heat exchanger” 224b is disposed on the opposite side of the electric heat pump 250 in thermal communication with the other side of the heat transfer fluid loop 256 via a corresponding inlet and outlet. The second heat exchanger 224b along includes an inlet for cool caustic line 260 and an outlet for warm caustic line 262, each in fluid communication with corresponding inlets and outlets of the caustic bath 210a. In various implementations, the heat exchanger 224b is or includes a condenser of the electrical heat pump 250.

[0068] When bottles 206 are first introduced to caustic bath 210a, a heat exchange occurs where the relatively cooler bottles 206 receive heat from the warm caustic solution of caustic bath 210a. Therefore, at a point close to the end of the bottles’ 206 progress through caustic bath 210a, the caustic solution is cooler than it was near the beginning of the track. To maintain the heat of the caustic solution, the water and energy reuse system 202 of system 200 takes advantage of the excess heat of rinse water in reservoir 218a, routing that heat through a heat pump 250 and into heat exchanger 224b. Thus, cool caustic solution flows down the cool caustic line 260 and receives heat from the warm heat transfer fluid within heat exchanger 224b. Then, warmer caustic solution returns to the caustic bath 210a via the warm caustic line 262.

[0069] The three loops of system 200 include (i) the loop of rinse water between reservoirs 218b and 218c through heat exchanger 224a, (ii) the heat transfer fluid loop 256 through the heat pump 250, and (iii) the caustic solution loop through heat exchanger 224b. Thus, system 200 is a “3-loop circulation” system.

[0070] In this way, rinse water from bottle rinsing station 214a is not simply wasted, but it is reused both for its heat energy and water content. The heat energy returns to the system 200 in the form of re -heated caustic solution. The water then returns to the system 200 in the form of rinse water for reservoir 218b. The overall system 200 saves water and energy compared to traditional systems. For example, the system 200 recirculates 8m³/hr of rinse water from the reservoir 218a, through the first heat exchanger 224a, and back to the second reservoir 218b for use in the second bottle rinsing station 214b. System 200 also recirculates 4m³/hr of rinse water from reservoir 218a for internal use, such as refiling the caustic baths 210 or other initial processes. System 200 also recirculates lm³/hr of rinse water to a crate washer. System 200 recirculates 6m³/hr of rinse water from the reservoir 218c, through the treatment system 234, and back to the nozzles 220i and 220j, losing only lm³/hr of wastewater from the treatment system 234. However, in other implementations, a variety of values for water use and reuse are possible with the system of this disclosure.

[0071] One will recognize the alternatives available in system 200 depending upon the specific use case. For example, caustic bath 210b may receive the re-heated caustic, or a different reservoir may be connected to the heat exchanger 224a. System 200 is simply one example of a variety of implementations of the water and energy reuse system 202 and a bottle washing system 204.

Example system #2

[0072] Fig. 3 illustrates system 300 which is substantially similar to system 200, where reference is made to the system 200 for a description of the common components. Just as in system 200, system 300 includes “3-loop circulation” system. System 300 includes the same fluid connections and heat exchange setup as in system 200. However, system 300 differs from system 200 in that system 300 does not include a water treatment system. Therefore, unlike system 200 with a separated “treatment loop”, system 300 includes no treatment loop. [0073] Three of the nozzles 320 of the nozzle array 316c of the bottle rinsing station 314c receive rinse water from the reservoir 318c. However, with the lack of a water treatment system, the other three nozzles, labeled nozzles 320i, 320j, and 320k, all receive fresh water (e.g., from a municipal water source). This system ensures a greater amount of fresh, municipal water rinses the bottles as they leave the system 300, however, less water may be recycled for the nozzles 320. One will recognize that different systems may have their desired implementation depending on a number of factors.

Example system #3

[0074] Fig. 4 illustrates system 400 which is similar to the above-described systems. System 400 is a “3-loop circulation” system, similar to system 200, where reference is made to the systems 200-300 for a description of the common components. However, system 400 includes an integrated “treatment loop” (different from the separate treatment loop in system 200).

[0075] System 400 includes a cold water line 432 in fluid communication with an outlet of heat exchanger 424a. Rather than providing cold water to a reservoir, as in system 200, the cold water leaving the heat exchanger 424a in system 400 is delivered to a water treatment system 434. After treatment, the water travels along treated water line 440 and back into the bottle rinsing station 414c. The treated water is then dispensed from the next-to-last two nozzles 420i and 420j of the nozzle array 416c. The final nozzle 420k of nozzle array 416c receives and dispenses fresh water (e.g., from a municipal supply).

[0076] Therefore, system 400 integrates the “treatment loop” into the rinse water loop by treating and reintroducing rinse water directly into the nozzle array 416c. The heat is transferred and reused similar to the above-described systems. One will recognize the alternatives available with system 400. For example, the treated water line may connect with a different nozzle array or set of nozzles.

Example System #4

[0077] Fig. 5 illustrates system 500 which is similar to the above-described systems, where reference is made to the systems 200-400 for a description of the common components. System 500 includes a “1-loop circulation” system with integrated “treatment loop.” That is, the reused rinse water of system 500 follows a path similar to system 400. The rinse water enters heat exchanger 524a to transfer its heat and is cooled before moving into water treatment system 534. After treatment, the treated water is reused in the bottle rinsing station 514c.

[0078] System 500 is different in that the water and energy reuse system 502 includes only a single heat exchanger 524a. Rather than include a heat pump and a second heat exchanger to reheat the caustic solution, the system 500 takes the heat from the rinse water of reservoir 518a and uses it for external purposes. For example, the warm fluid leaving the heat exchanger 524a is delivered to external device 570. External device 570 may be a heat pump or some other device capable of transferring heat energy. In some implementations, the external device 570 may facilitate heating of a structure or a workspace. In other implementations, the external device 570 may facilitate heating of some other manufacturing process. Overall, the heat from reservoir 518a is reused somewhere, but just not internal to the system 500.

Example System #5 [0079] Fig. 6 illustrates system 600, which is substantially similar to system 500, where reference is made to the systems 200-400 for a description of the common components. System 500 includes a “1-loop circulation” system with integrated “treatment loop.” That is, the reused rinse water of system 600 follows a path similar to system 500. The difference between system 600 and system 500 is that system 600 removes heat from the last reservoir in line closest to the bottle outlet, reservoir 618c, as opposed to the first reservoir 618a. The rinse water from reservoir 618c is used by the heat exchanger 624a to implement thermal energy in an external device. Then, the rinse water is treated and delivered back into a nozzle array.

[0080] One will appreciate the temperature difference between the first reservoir 618a and the third reservoir 618c. Depending on the particular process required, system 600 may be a more efficient setup in some implementations. One will appreciate the alternatives available with regard to reservoir placement, rinse water reuse, and heat energy utilization. For example, it is contemplated that the heat exchanger 624a may receive warmed rinse water from any of the reservoirs 618, including an intermediary reservoir between the first reservoir 618a and the last reservoir 618c.

Example Method

[0081] Fig. 7 illustrates an example method for any of the systems for water and energy reuse as described herein. For a water and energy reuse method 700, the bottle washing system includes a post-caustic bottle rinsing area with a plurality of bottle rinsing stations arranged in series, each of the bottle rinsing stations comprising a plurality of bottle rinsing nozzles and a reservoir adapted to collect rinse water dispensed from the plurality of bottle rinsing nozzles. [0082] First, the water and energy reuse method 700 includes a receiving step 702 wherein the system receives heated rinse water from the reservoir of one of the bottle rinsing stations at a rinse water inlet of a rinse water heat exchanger. For example, this step could be the flow of rinse water from reservoir 118a to heat exchanger 124 in system 100.

[0083] Next, a supplying step 704 includes supplying a source of cooled rinse water from a rinse water outlet of the rinse water heat exchanger. Then, a receiving step 706 includes receiving rinse water from the reservoir of one of the plurality of bottle rinsing stations at an inlet of a water treatment system. Next, a supplying step 708 includes supplying treated water from an outlet of the water treatment system to one or more of the bottle rinsing nozzles of the last of the plurality of the bottle rinsing station in the series.

[0084] In some implementations, further steps of the method 700 are included, as denoted by dotted line panes in Fig. 7. For example, a receiving step 710 may include receiving a heat transfer fluid at a heat transfer fluid inlet of the rinse water heat exchanger and a supplying step 712 may include supplying the heat transfer fluid heated by the heated rinse water to a heat transfer fluid outlet of the rinse water heat exchanger. Steps 710 and 712 may include receiving and supplying of a refrigerant, in some implementations.

[0085] In some implementations, a supplying step 714 includes supplying the source of cooled rinse water to the water treatment system from the rinse water outlet of the water heat exchanger. In other implementations, a supplying step 716 includes supplying the source of cooled rinse water to the reservoir of an intermediate one of the plurality of bottle rinsing stations in the series from the rinse water outlet of the rinse water heat exchanger. In some implementations, receiving rinse water at the inlet of a water treatment system comprises receiving rinse water from the reservoir of the last of the plurality of bottle rinsing stations in the series.

[0086] In some implementations, a supplying step 718 includes supplying the heated rinse water from the heat transfer fluid outlet of the rinse water heat exchanger to an external system for heat exchange. In some implementations, a receiving step 720 includes receiving the heat transfer fluid at the heat transfer fluid inlet of the rinse water heat exchanger from the external system.

In some implementations, an exchanging step 722 includes exchanging heat between a heat pump and the rinse water heat exchanger, a receiving step 724 includes receiving caustic from a caustic reservoir of bottle washing system at a caustic inlet of a caustic heat exchanger coupled to the heat pump for heat exchange therebetween, and a supplying step 726 includes supplying a source of heated caustic to the caustic reservoir from a caustic outlet of the caustic heat exchanger.

[0087] A number of example implementations are provided herein. However, it is understood that various modifications can be made without departing from the spirit and scope of the disclosure herein. As used in the specification, and in the appended claims, the singular forms “a,” “an,” “the” include plural referents unless the context clearly dictates otherwise. The term “comprising” and variations thereof as used herein is used synonymously with the term “including” and variations thereof and are open, non-limiting terms. Although the terms “comprising” and “including” have been used herein to describe various implementations, the terms “consisting essentially of’ and “consisting of’ can be used in place of “comprising” and “including” to provide for more specific implementations and are also disclosed. [0088] Disclosed are materials, systems, devices, methods, compositions, and components that can be used for, can be used in conjunction with, can be used in preparation for, or are products of the disclosed methods, systems, and devices. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutations of these components may not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a device is disclosed and discussed each and every combination and permutation of the device are disclosed herein, and the modifications that are possible are specifically contemplated unless specifically indicated to the contrary. Likewise, any subset or combination of these is also specifically contemplated and disclosed. This concept applies to all aspects of this disclosure including, but not limited to, steps in methods using the disclosed systems or devices. Thus, if there are a variety of additional steps that can be performed, it is understood that each of these additional steps can be performed with any specific method steps or combination of method steps of the disclosed methods, and that each such combination or subset of combinations is specifically contemplated and should be considered disclosed.

Claims

CLAIMS What is claimed is:

1. A water and energy reuse system for a bottle washing system, the bottle washing system including a post-caustic bottle rinsing area with a plurality of bottle rinsing stations arranged in a series, each of the plurality of bottle rinsing stations comprising a plurality of bottle rinsing nozzles and a reservoir adapted to collect rinse water dispensed from the plurality of bottle rinsing nozzles, the water and energy reuse system comprising: a rinse water heat exchanger with a rinse water inlet configured to be coupled to the reservoir of one of the plurality of bottle rinsing stations to receive heated rinse water and a rinse water outlet configured to supply a source of cooled rinse water; and a water treatment system with an inlet configured to be coupled to receive rinse water from the reservoir of one of the plurality of bottle rinsing stations and an outlet configured to be coupled to and supply treated water to one or more of the plurality of bottle rinsing nozzles of a last of the plurality of bottle rinsing stations in the series.

2. The water and energy reuse system of claim 1 , wherein the inlet of the rinse water heat exchanger is configured to be coupled to the reservoir of a first of the plurality of bottle rinsing stations in the series.

3. The water and energy reuse system of any of claims 1 or 2, wherein the water treatment system includes one or more of an ultrafiltration membrane, a nanofiltration membrane, or reverse osmosis filtration membrane.

4. The water and energy reuse system of any of claims 1-3, wherein the water treatment system is configured to produce the treated water with one or more of pH correction, particle removal, or sodium removal.

5. The water and energy reuse system of any of claims 1-4, wherein the rinse water heat exchanger further comprises a heat transfer fluid inlet configured to receive a heat transfer fluid and a heat transfer fluid outlet configured to supply the heat transfer fluid heated by the heated rinse water.

6. The water and energy reuse system of any of claims 1-5, wherein the rinse water outlet of the rinse water heat exchanger is configured to be coupled to the inlet of the water treatment system to supply the source of cooled rinse water to the water treatment system.

7. The water and energy reuse system of any of claims 1-5, wherein the rinse water outlet of the rinse water heat exchanger is configured to be coupled to the reservoir of an intermediate one of the plurality of bottle rinsing stations in the series.

8. The water and energy reuse system of any of claims 1-5, wherein the inlet of the water treatment system is configured to be coupled to the reservoir of the last of the plurality of bottle rinsing stations in the series.

9. The water and energy reuse system of any of claims 5-8, wherein the heat transfer fluid inlet and the heat transfer fluid outlet are configured to be coupled to an external system for heat exchange therebetween.

10. The water and energy reuse system of any of claims 1-8, further comprising: a heat pump coupled to the rinse water heat exchanger for heat exchange therebetween; and a caustic heat exchanger coupled to the heat pump for heat exchange therebetween, wherein the caustic heat exchanger comprises a caustic inlet configured to be coupled to a caustic reservoir of the bottle washing system and a caustic outlet configured to supply a source of heated caustic to the caustic reservoir.

11. The water and energy reuse system of claim 10, wherein the heat pump comprises an evaporator, wherein the evaporator includes a heat transfer fluid inlet and a heat transfer fluid outlet of the rinse water heat exchanger.

12. The water and energy reuse system of any of claims 10 or 11 , wherein the caustic heat exchanger further comprises a second heat transfer fluid inlet configured to receive a second heat transfer fluid and a second heat transfer fluid outlet configured to supply the second heat transfer fluid heated by the heat pump and the second heat transfer fluid.

13. The water and energy reuse system of claim 12, wherein the heat pump comprises a condenser, wherein the condenser includes the second heat transfer fluid inlet and the second heat transfer fluid outlet of the caustic heat exchanger.

14. A water and energy reuse method for a bottle washing system, the bottle washing system including a post-caustic bottle rinsing area with a plurality of bottle rinsing stations arranged in a series, each of the plurality of bottle rinsing stations comprising a plurality of bottle rinsing nozzles and a reservoir adapted to collect rinse water dispensed from the plurality of bottle rinsing nozzles, the water and energy reuse method comprising: receiving heated rinse water from the reservoir of one of the plurality of bottle rinsing stations at a rinse water inlet of a rinse water heat exchanger; supplying a source of cooled rinse water from a rinse water outlet of the rinse water heat exchanger; receiving rinse water from the reservoir of one of the plurality of bottle rinsing stations at an inlet of a water treatment system; and supplying treated water from an outlet of the water treatment system to one or more of the plurality of bottle rinsing nozzles of a last of the plurality of bottle rinsing stations in the series.

15. The water and energy reuse method of claim 14, further comprising: receiving a heat transfer fluid at a heat transfer fluid inlet of the rinse water heat exchanger; and supplying the heat transfer fluid heated by the heated rinse water to a heat transfer fluid outlet of the rinse water heat exchanger.

16. The water and energy reuse method of any of claims 14-15, further comprising: supplying the source of cooled rinse water to the water treatment system from the rinse water outlet of the rinse water heat exchanger.

17. The water and energy reuse method of any of claims 14-15, further comprising: supplying the source of cooled rinse water to the reservoir of an intermediate one of the plurality of bottle rinsing stations in the series from the rinse water outlet of the rinse water heat exchanger.

18. The water and energy reuse method of any of claims 14-15, wherein receiving rinse water at the inlet of a water treatment system comprises receiving rinse water from the reservoir of the last of the plurality of bottle rinsing stations in the series.

19. The water and energy reuse method of any of claims 15-18, further comprising: supplying the heated rinse water from the heat transfer fluid outlet of the rinse water heat exchanger to an external system for heat exchange; and receiving the heat transfer fluid at the heat transfer fluid inlet of the rinse water heat exchanger from the external system.

20. The water and energy reuse method of any of claims 14-18, further comprising: exchanging heat between a heat pump and the rinse water heat exchanger; receiving caustic from a caustic reservoir of a bottle washing system at a caustic inlet of a caustic heat exchanger coupled to the heat pump for heat exchange therebetween; and supplying a source of heated caustic to the caustic reservoir from a caustic outlet of the caustic heat exchanger.