Content-filling system and sterilizing method
A content-filling system ( 10 ) includes a water sterilization line ( 50 ) that sterilizes water without heating, an undiluted-solution sterilization line ( 70 ) that heats and sterilizes a product undiluted solution, and a filling device ( 20 ) that is connected to the water sterilization line ( 50 ) and the undiluted-solution sterilization line ( 70 ) and that fills the water and the product undiluted solution in bottles ( 100 ).
1 . A content-filling system comprising:
a water sterilization line that sterilizes water without heating;
an undiluted-solution sterilization line that heats and sterilizes a product undiluted solution;
a filling device that is connected to the water sterilization line and the undiluted-solution sterilization line and that fills the water and the product undiluted solution in a container; and
a control unit that controls the water sterilization line,
wherein the water sterilization line sterilizes the water by using an ultraviolet ray, and
wherein the control unit causes the water to be discharged to a location outside the water sterilization line in a case in which an irradiation amount or irradiance of the ultraviolet ray is equal to or less than a predetermined value.
2 . The content-filling system according to claim 1 , wherein at the water sterilization line, the water is sterilized by using the ultraviolet ray at least from a low-pressure mercury lamp or an intermediate-pressure mercury lamp.
3 . The content-filling system according to claim 1 , wherein the water sterilization line sterilizes the water by filtering the water using a sterile filter.
4 . The content-filling system according to claim 1 , wherein the product undiluted solution is diluted with the water by a factor that is greater than or equal to 1.1 and less than or equal to 100.
5 . The content-filling system according to claim 1 , wherein a mixing tank that mixes the water and the product undiluted solution is interposed between the water sterilization line and the filling device and between the undiluted-solution sterilization line and the filling device.
6 . The content-filling system according to claim 1 , wherein the filling device includes a plurality of filling nozzles that fill the water and the product undiluted solution, and the water sterilization line and the undiluted-solution sterilization line are connected to a corresponding one of the plurality of filling nozzles.
7 . A sterilizing method of sterilizing the content-filling system according to claim 1 ,
wherein the water sterilization line includes at least a water sterilizer,
wherein the water sterilizer includes at least one sterile filter and at least one sterilizer, and
wherein the sterilizing method comprises: a step of conducting a first integrity test for the at least one sterile filter;
a step of sterilizing the at least one sterile filter; and
a step of conducting a second integrity test for the at least one sterile filter.
8 . The sterilizing method according to claim 7 , further comprising: a step of sterilizing the at least one sterilizer.
9 . The sterilizing method according to claim 8 , wherein the step of sterilizing the at least one sterilizer includes:
a step of supplying hot water to the water sterilizer,
a step of circulating the hot water in a circulation system that includes the at least one sterilizer, and
a step of cooling the circulation system.
10 . The sterilizing method according to claim 8 , wherein the step of sterilizing the at least one sterilizer includes:
a step of supplying a chemical to the water sterilizer,
a step of circulating the chemical in a circulation system that includes the at least one sterilizer, and
a step of rinsing the circulation system.
11 . The sterilizing method according to claim 8 , wherein the step of sterilizing the at least one sterile filter is performed while the step of sterilizing the at least one sterilizer is performed.
12 . A content-filling system comprising:
a water sterilization line that sterilizes water without heating;
an undiluted-solution sterilization line that heats and sterilizes a product undiluted solution;
a filling device that is connected to the water sterilization line and the undiluted-solution sterilization line and that fills the water and the product undiluted solution in a container; and
a control unit that controls the water sterilization line,
wherein the water sterilization line includes at least a water sterilizer that sterilizes the water,
wherein the water sterilizer includes at least a sterile filter, and
wherein the control unit causes the water to be discharged to a location outside the water sterilization line in a case which a difference between pressure at a position upstream of the sterile filter and pressure at a position downstream of the sterile filter is a predetermined value or more.
13 . A content-filling system comprising:
a water sterilization line that sterilizes water without heating;
an undiluted-solution sterilization line that heats and sterilizes a product undiluted solution;
a filling device that is connected to the water sterilization line and the undiluted-solution sterilization line and that fills the water and the product undiluted solution in a container; and
a control unit that controls the water sterilization line,
wherein the control unit causes the water to be discharged to a location outside the water sterilization line in a case in which at least a number of a microbe or a number of a fine particle in the water that is sampled from the water sterilization line is a predetermined value or more.
14 . A content-filling system comprising:
a water sterilization line that sterilizes water without heating;
an undiluted-solution sterilization line that heats and sterilizes a product undiluted solution; and
a filling device that is connected to the water sterilization line and the undiluted-solution sterilization line and that fills the water and the product undiluted solution in a container;
wherein the filling device includes a water-filling device that is connected to the water sterilization line and an undiluted-solution-filling device that is connected to the undiluted-solution sterilization line, the water-filling device fills the water that is sterilized in the container, and the undiluted-solution-filling device fills the product undiluted solution that is sterilized in the container.
15 . The content-filling system according to claim 14 , wherein the water-filling device fills the water in the container when the container is empty, and a filling rate at which the water-filling device fills the water in the container is higher than a filling rate at which the undiluted-solution-filling device fills the product undiluted solution in the container.
16 . The content-filling system according to claim 14 , wherein the water-filling device includes a plurality of water-filling nozzles that fills the water, a snifting line for discharging gas in the container is connected to a corresponding one of the plurality of water-filling nozzles, and the water-filling device compresses and fills the water with the gas in the container being discharged via the snifting line.
17 . The content-filling system according to claim 16 , wherein a seal member that inhibits the gas in the container from leaking by coming into close contact with the container is disposed at an end of the plurality of water-filling nozzles, and the water-filling device compresses and fills the water with the seal member being in close contact with the container.
18 . The content-filling system according to claim 16 , wherein the undiluted-solution-filling device includes a plurality of undiluted-solution-filling nozzles that fills the product undiluted solution, and a diameter of the plurality of water-filling nozzles is larger than a diameter of the plurality of undiluted-solution-filling nozzles.
19 . The content-filling system according to claim 18 , wherein the diameter of the plurality of water-filling nozzles is greater than or equal to 1.2 times the diameter of the plurality of undiluted-solution-filling nozzles and less than or equal to 1.5 times the diameter of the plurality of undiluted-solution-filling nozzles.
20 . The content-filling system according to claim 14 , wherein the filling device includes a plurality of undiluted-solution-filling devices.
21 . The content-filling system according to claim 20 , further comprising: a plurality of undiluted-solution sterilization lines, wherein each of the plurality of undiluted-solution-filling devices is connected to a corresponding one of the plurality of undiluted-solution sterilization lines.
22 . The content-filling system according to claim 21 , wherein the plurality of undiluted-solution-filling devices include a first undiluted-solution-filling device that fills a product undiluted solution that has no flavor, and a second undiluted-solution-filling device that fills a product undiluted solution that has flavor.
23 . The content-filling system according to claim 22 , wherein the first undiluted-solution-filling device is contained in a space that is divided by a chamber wall,
wherein the chamber wall has a gap through which the container passes,
wherein a first wheel that includes a first gripper that conveys the container is disposed outside the space so as to be capable of opening and closing,
wherein a second wheel that includes a second gripper that conveys the container is disposed in the space so as to be capable of opening and closing,
wherein the second gripper receives the container from the first gripper in a case in which the first undiluted-solution-filling device fills the product undiluted solution that has no flavor in the container, and
wherein the second gripper moves to an open position so as not to interfere with the first gripper in a case in which the first undiluted-solution-filling device does not fill the product undiluted solution that has no flavor in the container.
24 . The content-filling system according to claim 23 , wherein the chamber wall includes a shutter that covers and uncovers the gap,
wherein the shutter covers the gap in a case in which the first undiluted-solution-filling device does not fill the product undiluted solution that has no flavor in the container, and
wherein the second gripper moves to the open position so as not to interfere with the shutter that covers the gap.
25 . A content-filling system comprising:
a water sterilization line that sterilizes water without heating;
an undiluted-solution sterilization line that heats and sterilizes a product undiluted solution; and
a filling device that is connected to the water sterilization line and the undiluted-solution sterilization line and that fills the water and the product undiluted solution in a container;
wherein the filling device includes a water-filling device that is connected to the water sterilization line and an undiluted-solution-filling device that is connected to the undiluted-solution sterilization line, and the water or the product undiluted solution is filled in the container by using only the water-filling device or the undiluted-solution-filling device, respectively.
26 . A content-filling system comprising:
a water sterilization line that sterilizes water without heating;
an undiluted-solution sterilization line that heats and sterilizes a product undiluted solution; and
a filling device that is connected to the water sterilization line and the undiluted-solution sterilization line and that fills the water and the product undiluted solution in a container;
wherein the water sterilization line includes a first water tank that stores the water, a water sterilizer that sterilizes the water that is stored in the first water tank, and a second water tank that stores the water that is sterilized by the water sterilizer, and
wherein the undiluted-solution sterilization line includes a first undiluted-solution tank that stores the product undiluted solution, a product-undiluted-solution sterilizer that heats and sterilizes the product undiluted solution that is stored in the first undiluted-solution tank, and a second undiluted-solution tank that stores the product undiluted solution that is sterilized by the product-undiluted-solution sterilizer.
27 . The content-filling system according to claim 26 , wherein the water sterilization line includes a plurality of water sterilizers.
28 . The content-filling system according to claim 26 , further comprising: a cap-sterilizing device that sterilizes a cap to be mounted on the container in which the water and the product undiluted solution are filled; and a bypass line that connects the water sterilization line and the cap-sterilizing device to each other and that is disposed downstream of the second water tank.
29 . The content-filling system according to claim 26 , wherein an addition unit that adds a solid into the product undiluted solution is disposed downstream of the second undiluted-solution tank.
30 . A content-filling system comprising:
a water sterilization line that sterilizes water without heating;
an undiluted-solution sterilization line that heats and sterilizes a product undiluted solution;
a filling device that is connected to the water sterilization line and the undiluted-solution sterilization line and that fills the water and the product undiluted solution in a container;
a preform-sterilizing device that sterilizes a preform;
a container-molding device that molds the container by using the preform; and
a container-sterilizing device that sterilizes the container, wherein the container-molding device molds the container without adjusting temperature of the container by using warm water.
31 . A content-filling system comprising:
a water sterilization line that sterilizes water without heating;
an undiluted-solution sterilization line that heats and sterilizes a product undiluted solution; and
a filling device that is connected to the water sterilization line and the undiluted-solution sterilization line and that fills the water and the product undiluted solution in a container;
wherein the water sterilization line is divided into a non-sterile zone in a non-sterile atmosphere, a first gray zone and a second gray zone that isolate the non-sterile atmosphere and a sterile atmosphere from each other, and a sterile zone in the sterile atmosphere, the non-sterile zone, the first gray zone, the second gray zone, and the sterile zone are arranged in this order from an upstream position to a downstream position in a direction in which the water is conveyed, a microbe in the water is killed in the first gray zone, and a state in which no microbe is present in the water is maintained in the second gray zone.