Rotary filling apparatus and methods

1. An apparatus for filling containers comprising:

a filler frame;

a rotary turret assembly rotatably coupled to the filler frame, the rotary turret assembly comprising a rotary base and a plurality of hollow columns mounted on the rotary base and arranged in a circle;

a filler plenum assembly underlying a portion of the rotary turret assembly, the filler plenum assembly comprising a plenum, wherein the plenum is in fluid communication with the hollow columns for a portion of each rotation of the rotary turret assembly;

a plurality of piston assemblies disposed in the hollow columns, the piston assemblies configured to move up and down within the hollow columns, wherein each piston assembly comprises

a piston body having a top and

a top hat assembly configured to releasably engage the top of the piston body, each top hat assembly comprising a cam contact member;

a release lever, wherein the piston body and the top hat assembly can release from one another when the release lever is engaged;

a lever actuator configured to contact the release lever when a container to be filled is absent;

a cam track operably connected to the filler frame; wherein rotation of the rotary column group causes the cam contact members of the piston assemblies to move over a surface of the cam track causing vertical movement of the top hat assemblies of the piston assemblies relative to the hollow columns they are disposed in; and

a fluid supply group in fluid communication with the plenum, the fluid supply group comprising a liquid supply tank, and a supply conduit providing fluid communication between the liquid supply tank and the plenum.

2. The apparatus for filling containers of claim 1 , the piston body further comprising a bottom and piston rings disposed around the piston body adjacent the bottom, the piston rings comprising an X-ray detectable material.

3. The apparatus for filling containers of claim 1 , the piston body having an outer diameter of about 1 inch to about 4 inches at its widest point.

4. The apparatus for filling containers of claim 1 , the piston body having an outer diameter of about 2 inches to about 3 inches at its widest point.

5. The apparatus for filling containers of claim 1 , the hollow columns comprising a channel extending from the top of the hollow columns to a vertical mid-point on the hollow columns.

6. The apparatus for filling containers of claim 1 , the piston assembly further comprising a shaft connecting the cam contact member and the top hat assembly.

7. The apparatus for filling containers of claim 1 , the cam track comprising a cam track surface, the cam track surface comprising a first rising portion corresponding to a filling phase, a second rising portion corresponding to an overfilling phase; a first declining portion corresponding to a purging phase; a first flat portion corresponding to a hold phase; and a second declining portion corresponding to a dispensing phase.

8. The apparatus for filling containers of claim 7 , wherein a vertical distance covered by the first rising portion is the same as the second declining portion.

9. The apparatus for filling containers of claim 7 , wherein a vertical distance covered by the first rising portion is at least about 0.25 inches.

10. The apparatus for filling containers of claim 7 , wherein a vertical distance covered by the second rising portion is the same as the first declining portion.

11. The apparatus for filling containers of claim 7 , wherein a vertical distance covered by the second rising portion is at least about 0.25 inches.

12. The apparatus for filling containers of claim 7 , wherein a horizontal distance covered by the first flat portion is about 20 to 60 percent of a horizontal distance covered by the first rising portion and the second rising portion combined.

13. The apparatus for filling containers of claim 7 , wherein a horizontal distance covered by the first flat portion is about 30 to 50 percent of a horizontal distance covered by the first rising portion and the second rising portion combined.

14. The apparatus for filling containers of claim 7 , wherein a vertical distance covered by the first declining portion is equal to at least about 5% of a vertical distance covered by the second declining portion.

15. The apparatus for filling containers of claim 7 , wherein a vertical distance covered by the first declining portion is equal to at least about 10% of a vertical distance covered by the second declining portion.

16. The apparatus for filling containers of claim 7 , wherein the first rising portion and the second rising portion together cause the piston to move up in the hollow column such that a volume of about 50 ml to about 3000 ml of a liquid food material is drawn into a bottom portion of the hollow column.

17. The apparatus for filling containers of claim 7 , wherein the first rising portion and the second rising portion together cause the piston to move up in the hollow column such that a volume of about 50 ml to about 1500 ml of a liquid food material is drawn into a bottom portion of the hollow column.

18. The apparatus for filling containers of claim 7 , wherein the first rising portion and the second rising portion together cause the piston to move up in the hollow column such that a volume of about 300 ml to about 1000 ml of a liquid food material is drawn into a bottom portion of the hollow column.

19. The apparatus for filling containers of claim 7 , wherein a slope of the first rising portion is greater than the absolute value of a slope of the second declining portion.

20. The apparatus for filling containers of claim 7 , the cam contact member comprising a cam roller.