Method for controlling the operation of an aseptic filling machine

1. Method of operation of an aseptic product filling machine, the operation comprising:

a pre-production phase in which sterilization, filling and closing stations of the machine are sterilized, and a production phase in which a sterilization, filling and closing of a plurality of holders takes place at the respective stations,

in which, during the operation, control parameters of the stations are monitored for remaining in a pre-defined range,

in which the monitoring comprises a measuring of the control parameters by means of sensors, a diagnosing of the measured control parameters and a storing of the measured control parameters, and

in which the control parameters have been classified into a category of supercritical and a category of subcritical control parameters,

wherein the method further comprises the steps of:

performing a pre-production test procedure during the pre-production phase in which at least the subcritical control parameters are measured, diagnosed and stored;

checking if the subcritical control parameters are within their range;

starting the production phase if all of the subcritical control parameters are indeed within their range; and

measuring, diagnosing and storing the supercritical control parameters and not measuring, diagnosing and storing the subcritical control parameters during the production phase.

2. Method according to claim 1 , wherein at least part of the pre-production test procedure is performed after the sterilization of the stations has been completed.

3. Method according to claim 1 , wherein at least some of the sensors for measuring the control parameters are pressure sensors, flow meters or flow switches.

4. Method according to claim 1 , wherein during the pre-production phase both the supercritical and subcritical control parameters are measured, diagnosed and stored, after which both the supercritical and subcritical control parameters are checked for being within their range, and the production phase is started if both the supercritical and subcritical control parameters are indeed within their range.

5. Aseptic filling machine comprising:

a sterilization station for sterilizing holders with a sterilization medium and drying the sterilized holders with a drying gas;

a filling station for filling the sterilized dried holders with a product;

a closing station for closing the filled holders with a sealing element; and

a control unit for performing the method of claim 1 .

6. Method of operation of an aseptic product filling machine, the operation comprising:

a pre-production phase in which sterilization, filling and closing stations of the machine are sterilized, and a production phase in which a sterilization, filling and closing of a plurality of holders takes place at the respective stations,

in which, during the operation, control parameters of the stations are monitored for remaining in a pre-defined range,

in which the monitoring comprises a measuring of the control parameters by means of sensors, a diagnosing of the measured control parameters and a storing of the measured control parameters, and

in which the control parameters have been classified into a category of supercritical and a category of subcritical control parameters,

wherein the method further comprises the steps of:

performing a pre-production test procedure during the pre-production phase in which at least the subcritical control parameters are measured, diagnosed and stored;

checking if the subcritical control parameters are within their range;

starting the production phase if all of the subcritical control parameters are indeed within their range; and

measuring, diagnosing and storing the supercritical control parameters and not measuring, diagnosing and storing the subcritical control parameters during the production phase;

in which the machine comprises at least one main medium feed line which splits up into a plurality of branch medium feed lines,

in which a main sensor is provided for measuring a control parameter at the main medium feed line and branch sensors are provided for measuring a similar type of control parameter at their corresponding branch medium feed line, and

wherein the control parameter to be measured by the main sensor has been classified as being one of the supercritical control parameter and the control parameters to be measured by the branch sensors have been classified as being one of the subcritical control parameters,

wherein, during the pre-production phase, the pre-production test procedure further comprises the step of measuring, diagnosing and storing the control parameters in at least the branch medium feed lines, and

wherein, during the production phase, the method further comprises the step of measuring, diagnosing and storing the control parameter in the main medium feed line and not measuring, diagnosing and storing the control parameters in the branch medium feed lines.

7. Method according to claim 6 , in which the stations of the machine comprise a plurality of holder positions for sterilizing, filling and/or closing a plurality of holders at the respective stations at the same time, in which the main medium feed line is connected to a medium supply, and in which, during the production phase, medium is distributed over the plurality of holder positions at the same time via distribution nozzles at the ends of the branch medium feed lines,

wherein, during the pre-production phase, the pre-production test procedure further comprises the step of measuring, diagnosing and storing a flow of the medium in at least the branch medium feed lines, and

wherein, during the production phase, the method further comprises the step of measuring, diagnosing and storing a flow of the medium in the main medium feed line and not measuring, diagnosing and storing the flow of sterilization medium in the individual branch medium feed lines.

8. Method according to claim 7 , in which the main medium feed line is connected to a sterilization medium supply, and in which, during the production phase, sterilization medium is distributed over the plurality of holder positions at the same time via distribution nozzles at the ends of the branch medium feed lines,

wherein, during the pre-production phase, the pre-production test procedure further comprises the step of measuring, diagnosing and storing a flow of the sterilization medium in at least the branch medium feed lines, and

wherein, during the production phase, the method further comprises the step of measuring, diagnosing and storing a flow of the sterilization medium in the main medium feed line and not measuring, diagnosing and storing the flow of sterilization medium in the individual branch medium feed lines.

9. Method according to claim 7 , in which the main medium feed line is connected to a drying gas supply, and in which, during the production phase, drying gas is distributed over the plurality of holder positions at the same time via distribution nozzles at the ends of the branch medium feed lines,

wherein, during the pre-production phase, the pre-production test procedure further comprises the step of measuring, diagnosing and storing a flow of the drying gas in at least the branch medium feed lines, and

wherein, during the production phase, the method further comprises the step of measuring, diagnosing and storing a flow of the drying gas in the main medium feed line and not measuring, diagnosing and storing the flow of drying gas in the individual branch medium feed lines.

10. Method according to claim 7 , in which the main medium feed line is connected to a purge medium supply, and in which, during the production phase, purge medium is distributed over the plurality of holder positions at the same time via distribution nozzles at the ends of the branch medium feed lines,

wherein, during the pre-production phase, the pre-production test procedure further comprises the step of measuring, diagnosing and storing a flow of the purge medium in at least the branch medium feed lines, and

wherein, during the production phase, the method further comprises the step of measuring, diagnosing and storing a flow of the purge medium in the main medium feed line is measured, diagnosed and stored and not measuring, diagnosing and storing the flow of purge medium in the individual branch medium feed lines.

11. Method of operation of an aseptic product filling machine, the operation comprising:

a pre-production phase in which sterilization, filling and closing stations of the machine are sterilized, and a production phase in which a sterilization, filling and closing of a plurality of holders takes place at the respective stations,

in which, during the operation, control parameters of the stations are monitored for remaining in a pre-defined range,

in which the monitoring comprises a measuring of the control parameters by means of sensors, a diagnosing of the measured control parameters and a storing of the measured control parameters, and

in which the control parameters have been classified into a category of supercritical and a category of subcritical control parameters,

wherein the method further comprises the steps of:

performing a pre-production test procedure during the pre-production phase in which at least the subcritical control parameters are measured, diagnosed and stored;

checking if the subcritical control parameters are within their range;

starting the production phase if all of the subcritical control parameters are indeed within their range; and

measuring, diagnosing and storing the supercritical control parameters and not measuring, diagnosing and storing the subcritical control parameters during the production phase,

wherein a number of subsequent pre-production and production phases are performed after each other, wherein sterilized, filled and closed holders of a particular production phase are only released for distribution after the pre-production test procedure which is performed after this particular production phase has a positive outcome.