US20120102883A1

US20120102883A1 - System For Producing Sterile Beverages And Containers Using Electrolyzed Water

Info

Publication number: US20120102883A1
Application number: US12/938,882
Authority: US
Inventors: Subodh Raniwala; Amenah Ibrahim; Julie Kuruc; Greg Schimmel; Kevin Evans
Original assignee: Stokely Van Camp Inc
Current assignee: Stokely Van Camp Inc
Priority date: 2010-11-03
Filing date: 2010-11-03
Publication date: 2012-05-03
Also published as: RU2013125238A; AR083683A1; JP2014500830A; BR112013010904A2; RU2554015C2; CN103269972A; EP2635521A1; MX2013004915A; AU2011323803A1; WO2012061139A1; BR112013010904A8; CN103269972B; CA2816736A1

Abstract

A system and method of producing sterile beverages and containers, e.g., cleaning, sterilizing, and pre-sterilizing the bottles, the caps, and the critical surfaces using electrolyzed water. The sterilization system may include a mechanical sprayer that sprays electrolyzed water on the bottles, the caps, and the critical surfaces. In another embodiment, the sterilization system may include a fog generator connected to an electrolyzed water generator that produces a fog within a closed sterilization enclosure to sterilize the bottles, the caps, and the critical surfaces. Additionally, further, in yet another embodiment, the sterilization system may include an electrostatic fog generator connected to an electrolyzed water generator that produces an electrostatic, positively-charged fog within a closed sterilization enclosure. The electrostatic, positively-charged fog is attracted to the negatively charged or grounded bottles, caps, and critical surfaces to sterilize the bottles, the caps, and the critical surfaces.

Description

FIELD OF THE INVENTION

This invention relates generally to a method and a system for producing sterile beverages and containers, e.g., cleaning, sterilizing, and pre-sterilizing the containers, caps, and critical surfaces, and more specifically to the sterilizing of the containers, caps, and critical surfaces using electrolyzed water.

BACKGROUND OF THE INVENTION

The two most common processes to produce sterile acid non-carbonated beverages without preservatives are hot fill and aseptic. Both of these processes have inherent cost disadvantages and are not very sustainable. The hot fill process requires heavy weight bottles and excessive use of water resources. Additionally, the hot fill process is not economical due to the cost of petroleum based resins used to make the bottles. The aseptic processes are inherently capital intensive and inefficient as they require a high level of sophistication and built-in cycles that are associated with increased line down time as compared to hot fill.
Additionally, one of the major disadvantages of current aseptic processes is the need to sterilize all components of the package (caps, bottles) and assemble them in a controlled environment during bottle filling to avoid secondary contamination. The critical surfaces that are exposed to product are also sterilized before the initiation of the production cycle. In the event of loss of sterility due to violation of critical control points, these surfaces need to be re-sterilized before initiation of production. The current state of technology uses chemicals to sterilize caps, bottles & critical surfaces. Chemicals used currently require a water rinse to remove the residual chemical to prevent an adulteration issue. Recently, there have been developments to allow Electron Beam (E-Beam) based systems to accomplish the sterilization of the caps and the bottles. However, these systems are expensive and require more extensive health and safety requirements.
Thus, while various methods and systems for producing sterile beverages and containers according to the prior art provide a number of advantageous features, they nevertheless have certain limitations. The present invention seeks to overcome certain of these limitations and other drawbacks of the prior art, and to provide new features not heretofore available.

SUMMARY OF THE INVENTION

Accordingly, there is provided a sterilization system used to achieve sterile beverages and sterilize bottles and caps, wherein the bottles contain the sterile beverage and the caps cover the bottles, the sterilization system comprises: a bottle sterilizer for sterilizing the bottles, wherein the bottle sterilizer discharges electrolyzed water onto the bottles; a cap sterilizer for sterilizing the caps, wherein the cap sterilizer discharges electrolyzed water onto the caps; and a filler station that includes a filler sterilizer and a filler that fills the bottles with the beverage and caps the bottles, wherein the filler sterilizer sterilizes the filler station before the initiation of production by discharging electrolyzed water on the product-contact surfaces. Additionally, the bottle sterilizer, the cap sterilizer, and the filler sterilizer may include a mechanical sprayer that includes nozzles that discharge a spray of electrolyzed water onto the bottles, the caps, and the product-contact surfaces respectively. Also, the bottle sterilizer, the cap sterilizer, and the filler sterilizer may include a mechanical fog generator that discharges a fog of electrolyzed water onto the bottles, the caps, and the product-contact surfaces respectively. Further, the bottle sterilizer, the cap sterilizer, and the filler sterilizer may include an electrostatic fog generator that discharges an electrostatically charged fog of electrolyzed water onto the bottles, the caps, and the product-contact surfaces respectively.
In another embodiment according to this invention, a sterilization system used to achieve sterile beverages and sterilize bottles and caps, wherein the bottles contain the sterile beverage and the caps cover the bottles, the sterilization system comprises: an electrolyzed water generator that produces electrolyzed water; a bottle station for sterilizing the bottles, the bottle station includes a bottle loader for loading the bottles, a bottle conveyor for transporting the bottles, and a bottle rinser connected to the electrolyzed water generator that sprays the electrolyzed water onto the bottles; a cap station for sterilizing the caps, the cap station includes: a cap loader for loading the caps, a cap conveyor for transporting the caps, and a cap rinser connected to the electrolyzed water generator that sprays the electrolyzed water on the caps; a filler station connected to the bottle station and the cap station, wherein the filler station includes a filler with critical surfaces that are potential product-contact surfaces during the filling operation, and wherein the filler fills the bottles with the beverage and caps the bottles after the bottles are filled with the beverage, and wherein the filler station further includes a spray device connected to the electrolyzed water generator that sprays the electrolyzed water onto the critical surfaces of the filler. The sterilization system may further include a sterilization enclosure that fully encloses the filler that maintains aseptic conditions for the bottles, the caps, and the critical surfaces, wherein the sterilization enclosure may include a HEPA air filter to provide positive air pressure and proper air flow regimes throughout the sterilization enclosure.
In another embodiment according to this invention, a sterilization system used to achieve sterile beverages and sterilize bottles and caps, wherein the bottles contain the sterile beverage and the caps cover the bottles, the sterilization system comprises: a bottle station that includes a bottle loader for loading the bottles and a bottle conveyor for transporting the bottles; a cap station that includes a cap loader for loading the caps and a cap conveyor for transporting the caps; a filler station connected to the bottle station and the cap station, wherein the filler station includes a filler with critical surfaces that are potential product-contact surfaces during the filling operation, and wherein the filler fills the bottles with the beverage and caps the bottles after the bottles are filled with the beverage; a sterilization enclosure that fully encloses the filler, wherein the sterilization enclosure maintains aseptic conditions for the bottles, the caps, and the critical surfaces; an electrolyzed water generator that produces electrolyzed water; a fog generator connected to the electrolyzed water generator, wherein the fog generator produces a fog of electrolyzed water that is dispersed within the sterilization enclosure, wherein the fog of electrolyzed water sterilizes the bottles, caps, and critical surfaces. Additionally, the fog generator may produce an electrostatic, positively-charged fog of electrolyzed water, wherein the bottles, the caps, and the critical surfaces are negatively charged or grounded, thereby the bottles, the caps, and the critical surfaces attract the electrostatic, positively-charged fog of electrolyzed water.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic view of a sterilization system according to the present invention;

FIG. 1B is an exploded schematic view of a bottle station of the sterilization system depicted in FIG. 1A according to the present invention;

FIG. 1C is an exploded schematic view of a cap station of the sterilization system depicted in FIG. 1A according to the present invention;

FIG. 1D is an exploded schematic view of a filler station of the sterilization system depicted in FIG. 1A according to the present invention;

FIG. 2 is a side-view of the bottle station of the sterilization system depicted in FIGS. 1A and 1B according to the present invention;

FIG. 3 is a side-view of the cap station of the sterilization system depicted in FIGS. 1A and 1C according to the present invention;

FIG. 4A is a schematic view of an alternative embodiment of a cap station of the sterilization system depicted in FIG. 1A;

FIG. 4B is a side-view of the cap station depicted in FIG. 4A;

FIG. 5 illustrates an alternative embodiment of a sterilization system according to the present invention;

FIG. 6 illustrates an alternative embodiment of a sterilization system according to the present invention;

FIG. 7 illustrates an alternative embodiment of a sterilization system according to the present invention; and

FIG. 8 illustrates an alternative embodiment of a sterilization system according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1A illustrates a first embodiment of the invention, a sterilization system 100 used to achieve sterile beverages and to sterilize containers or bottles 102, caps 104, and critical surfaces. The bottles 102 may contain the sterile beverage and the caps 104 may cover the bottles 102. The critical surfaces generally include those surfaces on the equipment that come in contact with the product or product-contact surfaces and thereby must be sterile to maintain and produce sterile beverages. In one exemplary embodiment, the sterilization system 100 generally includes a bottle station 120, a cap station 140, and a filler station 160. The sterilization system 100 may utilize electrolyzed water to sterilize the bottles 102, the caps 104, and critical surfaces.
Electrolyzed water may be produced by an electrolyzed water system or an electrolyzed water generator 110 known and used in the art, such as those provided by various suppliers and/or manufacturers. For example, the electrolyzed water generator 110 may be an Ecaflo™ model (such as AQ50) manufactured and/or sold by Trustwater™ to produce the electrolyzed water. Generally, one exemplary process that produces electrolyzed water consists of passing water of varying mineralization through an electrochemical cell which results in two distinct electrically opposite streams, a negatively charged solution and a positively charged solution. The negatively charged solution and the positively charged solution may be mixed to modulate the pH and affect the sanitizing functionality of the electrolyzed water for sterilization. Additionally, there are other methods, processes, and/or system that may produce electrolyzed water for the sterilization system 100 without departing from this invention. The electrolyzed water generator 110 should be capable of producing electrolyzed water at a concentration range of approximately 50-1000 parts-per-million (PPM) as measured as free chlorine and a temperature range of approximately 10-65 degrees Celsius. The electrolyzed water generator 110 may deliver a higher conversion of the sodium chloride in the electrolysis process and produce electrolyzed water with reduced chloride content. Lower chloride content is required to minimize any corrosion issues in the beverage filling system.
As illustrated in FIGS. 1A and 1B, the sterilization system 100 may include the bottle station 120. The bottle station 120 may include a bottle loader 122, a bottle conveyor(s) 124, and a bottle rinser 126. The bottle loader 122 may consist of a container that holds fully formed unsterilized or unsanitized empty bottles 102. Additionally, the bottle loader 122 may include a device (not shown) within the container to automatically load the bottles 102 on to the bottle conveyor 124. An exemplary configuration of the bottle station 120 will be described below. The bottle station 120 may be other types and/or configurations of bottle stations without departing from this invention.
The bottler rinser 126 may include a bottle spray device 128 and a bottle rinser conveyor 130. A side view of the bottle rinser 126 is illustrated in FIG. 2. Generally, the bottle rinser 126 may spray or dispense a liquid on the bottles 102 as the bottles 102 pass through a given location. Specifically, the bottle rinser 126 may spray electrolyzed water on the bottles 102 as the bottles 102 pass through a bottle enclosure 134. The bottle spray device 128 may include one or more nozzles 132 to spray electrolyzed water onto the bottles 102 both internally and externally.
The bottle rinser 126 may spray electrolyzed water on the bottles 102 to sterilize or sanitize the bottles 102 internally and externally prior to filling the bottles 102. Specifically, the nozzles 132 spray a pre-set amount of electrolyzed water on the bottles 102. The bottle spray device 128 of the bottle rinser 126 may be connected or associated with an electrolyzed water generator 110. In one embodiment of the invention, the nozzles 132 may spray electrolyzed water at a low concentration, low temperature, and a high dwell time. For example, the nozzles 132 may spray electrolyzed water at a concentration range of approximately 50 to 100 PPM as measured as free chlorine, a temperature range of approximately 10 to 30 degrees Celsius, and a time range of approximately 5-30 minutes dwell time. In another embodiment of this invention, the nozzles 132 may spray electrolyzed water a high concentration, high temperature, and a low dwell time. For example, the nozzles 132 may spray electrolyzed water at a concentration range of approximately 100 to 1000 PPM as measured as free chlorine, a temperature range of approximately 25 to 65 degrees Celsius, and a time range of approximately 5 to 30 seconds dwell time.
The bottle rinser conveyor 130, as illustrated in FIGS. 1A and 1B, may be a linear conveyor. The linear bottle rinser conveyor 130 is inline with the other conveyors leading to the filler station 160. Additionally, the bottle rinser conveyor 130 may be configured to invert the position of the bottles 102, so that the opening of the bottles 102 are downwardly or side facing when the bottles 102 pass by the nozzles 132. At this point, the bottles 102 may then be sprayed by the nozzles 132. Once the bottles 102 are sprayed with electrolyzed water, the bottle rinser conveyor 130 may then again invert the position of the bottles 102 to an upright position with the opening facing upwardly.
Additionally, without departing from this invention, the bottle rinser 126 may include a bottle enclosure 134. The bottle enclosure 134 may be used to contain the electrolyzed water spray. The bottle enclosure 134 may include panels that surround an area around or associated with the area around the bottle spray device 128 and the bottle rinser conveyor 130. The bottle enclosure 134 may also be a cabinet surrounding the spraying area on the bottles 102.
During the spraying of the bottles 102 with electrolyzed water, the bottles 102 may contain a small residue of the electrolyzed water that may remain after the sterilization of the bottles 102. The electrolyzed water inside the bottles 102 is not an adulteration issue or product safety issue. In many cases, there is no significant sensory impact. However, to help remove this residue of electrolyzed water, a sterile air blower 136 may be included with the bottle rinser 126 without departing from the invention. The sterile air blower 136 may provide a pressurized blow of sterile air inside the bottles 102. The sterile air blower 136 may provide the blow of sterile air when the bottle 102 is inverted with the opening facing downward or with the bottle upright with the opening facing upward. This blow of sterile air may be sufficient to remove the majority of residual electrolyzed water.
Additionally, as illustrated in FIGS. 1A and 1C, the sterilization system 100 may include a cap station 140. The cap station 140 may include a cap loader 142, a cap conveyor(s) 144, and a cap rinser 146. The cap loader 142 may include a container that holds unsterilized or unsanitized caps 104. Additionally, the cap loader 142 may include a device (not shown) within the container to automatically load the caps 104 on to the cap conveyor 144. An exemplary configuration of the cap station 140 will be described below. The cap station 140 may be other types and/or configurations of cap stations without departing from this invention.
As further shown in FIG. 1C, the cap rinser 146 may include a cap spray device 148 and a cap rinser conveyor 150. A side view of the cap rinser 146 is illustrated in FIG. 3. Generally, the cap rinser 146 may spray or dispense a liquid on the caps 104 as the caps 104 pass through a given location. Specifically, the cap rinser 146 may spray electrolyzed water on the caps 104 as the caps 104 pass through a cap enclosure 154. The cap spray device 148 may include one or more nozzles 152 to spray electrolyzed water onto the caps 104.
The cap rinser 146 may spray electrolyzed water on the caps 104 to sterilize or sanitize the caps 104. Specifically, the nozzles 152 spray a pre-set amount of electrolyzed water on the caps 104. The cap spray device 148 may be connected or associated with an electrolyzed water generator 110. In one embodiment of the invention, the nozzles 152 may spray electrolyzed water at a low concentration, low temperature, and a high dwell time. For example, the nozzles 152 may spray electrolyzed water at a concentration range of approximately 50 to 100 PPM as measured as free chlorine, a temperature range of approximately 10 to 30 degrees Celsius, and a time range of approximately 5 to 30 minutes dwell time. In another embodiment of this invention, the nozzles 152 may spray electrolyzed water a high concentration, high temperature, and a low dwell time. For example, the nozzles 152 may spray electrolyzed water at a concentration range of approximately 100 to 1000 PPM as measured as free chlorine, a temperature range of approximately 25 to 65 degrees Celsius, and a time range of approximately 5 to 30 seconds dwell time.
The cap rinser conveyor 150, as illustrated in FIG. 1C, may be a linear conveyor. The linear cap rinser conveyor 150 is inline with the other conveyors leading to the filler station 160. Additionally, the cap rinser conveyor 150 may be configured to invert the position of the caps 104, so that the caps 104 are downwardly or sideways facing when the caps 104 pass by the cap spray device 148. At this point, the caps 104 may then be sprayed by the nozzles 152. Once the caps 104 are sprayed with electrolyzed water, the cap rinser conveyor 150 may then again invert the position of the caps 104 to an upright position with the cap facing upwardly.
Additionally, without departing from this invention, the cap rinser 146 may include a cap enclosure 154. The cap enclosure 154 may be used to contain the electrolyzed water spray. The cap enclosure 154 may include panels that surround an area around or associated with the area around the cap spray device 148 and the cap rinser conveyor 150. The cap enclosure 154 may also be a cabinet surrounding the spraying area on the caps 104.
During the spraying of the caps 104 with electrolyzed water, the caps 104 may contain a small residue of the electrolyzed water that may remain after the sterilization of the caps 104. The electrolyzed water inside the caps 104 is not an adulteration issue or product safety issue. In many cases, there is no significant sensory impact. However, to help remove this residue of electrolyzed water, a sterile air blower 156 may be included with the cap rinser without departing from the invention. The sterile air blower 156 may provide a pressurized blow of sterile air on or inside the caps 104. The sterile air blower 156 may provide the blow of sterile air when the cap 104 is inverted with the opening facing downward or with the cap upright with the opening facing upward. This blow of sterile air may be sufficient to remove the majority of residual electrolyzed water.
In another embodiment of the sterilization system, the cap station 140 may include multiple cap loaders 142. Additionally, the cap rinser 146 may be supplemented or replaced by submersing the caps 104 in electrolyzed water while in the cap loader 142. The cap loader(s) 142 may be filled with electrolyzed water at a low concentration, such as 50 to 100 PPM as measured as free chlorine, and a low temperature, such as 10 to 30 degrees Celsius to sterilize or sanitize the caps 104 while the caps 104 are being loaded and prior to the caps 104 being loaded onto the cap conveyor 144.
In yet another embodiment of the sterilization system, as illustrated in FIGS. 4A and 4B, the cap station 140 may include an immersion station 147. The immersion station 147 may supplement or replace the cap rinser 146. The immersion station 147 may be in the form of a tank, vat, or container that is filled with electrolyzed water. The immersion station 147 may be in line and connected with the cap conveyor 144. For example, as the caps 104 are conveyed along the cap conveyor 144, the caps 104 may be directed or conveyed into the immersion station 147 where the caps 104 may be completely immersed in electrolyzed water. The caps 104 may then be directed or conveyed out of the immersion station and back onto the cap conveyor 144 towards the filling station 160. The immersion station 147 may be filled with electrolyzed water at a low concentration, such as 50 to 100 PPM as measured as free chlorine, and a low temperature, such as 10 to 30 degrees Celsius to sterilize or sanitize the caps 104 while the caps 104 are conveyed through and immersed in the immersion station 147. Additionally, the immersion station 147 may be filled with electrolyzed water a higher concentration and a higher temperature as disclosed above. As was previously described, a sterile air blower may be included to help remove any residual electrolyzed water following the immersion station 147.
Additionally, as illustrated in FIGS. 1A and 1D, the sterilization system may include the filler station 160. The filler station 160 may consist of a filler 162 and a filler conveyor system 164. The filler 162 may be a rotary filler as illustrated in FIG. 1D. Additionally, the filler 162 may be other types and/or configurations of filling systems without departing from this invention. The filler 162 may receive the bottles 102 from the bottle conveyor 124 and fill the bottles 102 with a beverage using a filling head 168 on the filler 162. Also, the filler 162 may include a capper that receives the caps 104 from the cap conveyor 144 and places the caps 104 on the bottles 102 after the bottles 102 have been filled. Additionally, there may be a cap tightening device 166 on the filler 162 to ensure the caps 104 are sealed and tightened onto the bottles 102. The filler 162 may perform other operations without departing from this invention, such as sealing the bottle along the rim of the bottle after filling and prior to placing the caps 104 on the bottles 102. The filler station 160 also includes a filler conveyor system 164 which may transport the filled and capped bottles 102 from the filler 162 to a location where the bottles 102 can be packed and prepared for shipping.
In an embodiment of this invention, electrolyzed water may be used to pre-sterilize the system 100 before the initiation of production and prior to loading and filling the bottles 102 and the caps 104. Additionally, electrolyzed water may be used to sterilize the system 100 if sterility is lost, such as for equipment maintenance or component problems which require intervention by an operator or technician. For example, electrolyzed water may be used for the sterilization of critical surfaces on the system. Critical surfaces may include surfaces or equipment on the filler, such as a filling chamber (the internal chamber of the filler 162), the filler heads 168 (which connect or associate with the bottles 102 to fill the bottles 102 with beverage), the cap tightening device 166 (which tightens the caps 104 onto the bottles 102), or any other surfaces that may contact the areas on the bottles 102 or the caps 104 that may come in contact with the beverage.
Additionally, electrolyzed water may be used to help maintain sterility of the system 100 and critical surfaces during the filling process. For example, as was described above for the bottle rinser 126 and the cap rinser 146, the filler station 160 may include a filler spray device 170. The filler spray device 170 may consist of one or more nozzles 172. The nozzles 172 may spray electrolyzed water on the bottles 102 and/or caps 104 throughout the filling process. For example, the nozzles 172 may spray electrolyzed water on the bottles 102 when a bottle 102 is raised or connected to the filling head 168. Additionally, the nozzles 172 may spray electrolyzed water on the capping area, when the caps 104 are placed on the bottles 104. This spray of electrolyzed water may be required to maintain sterilized/clean conditions in the product path until a hermetic seal is accomplished. The nozzles 172 may continuously spray the electrolyzed water on the critical surfaces of the system. Additionally the spray of electrolyzed water on the critical surfaces may be intermittent, such as spraying approximately once every 15 seconds, 30 seconds, or every minute, or other time ranges as required to maintain sterility of the critical surfaces. Without departing from this invention, the filling station may also include a separate capper or capping station that receives the caps 104, places the caps 104 on the bottles 102, and tightens or seals the caps 104 onto the bottles 102. The capping station may be a rotary capper as known and used in the art. This capping station may also include a nozzle that sprays electrolyzed water on the capping area, where the caps 104 are placed and tightened onto the bottles 102.
As was described above, a small residue may remain on the bottles 102 and/or caps 104 after the sterilization. This electrolyzed water that may remain on the bottles 102 and/or caps 104 after the sterilization is not an adulteration issue or product safety issue. In many cases, there is no significant sensory impact. However, to help remove this residue of electrolyzed water, a sterile air blower 174 may be included with the filler spray devices 170 without departing from this invention. The sterile air blower 174 may provide a blow of pressurized sterile air on or inside the bottles 102 and/or the caps 104 during the filling and/or capping process. The blow of sterile air may be sufficient to remove the majority of residual electrolyzed water.
Specifically, the nozzles 172 spray a pre-set amount of electrolyzed water on the bottles 102 and/or caps 104 during the filling process. The filler spray device 170 may be connected or associated with an electrolyzed water generator 110. In one embodiment of the invention, the nozzles 172 may spray electrolyzed water at a low concentration, low temperature, and a high dwell time. For example, the nozzles 172 may spray electrolyzed water at a concentration range of approximately 50 to 200 PPM as measured as free chlorine, a temperature range of approximately 10 to 35 degrees Celsius, and a time range of approximately 5 to 30 minutes dwell time. In another embodiment of this invention, the nozzles 172 may spray electrolyzed water a high concentration, high temperature, and a low dwell time. For example, the nozzles 172 may spray electrolyzed water at a concentration range of approximately 200 to 1000 PPM as measured as free chlorine, a temperature range of approximately 25 to 60 degrees Celsius, and a time range of approximately 5 to 30 seconds dwell time.
FIG. 1A also includes a sterilization enclosure 180 as part of the sterilization system 100 described above. This sterilization enclosure 180 may be utilized to maintain aseptic conditions for the bottles 102, caps 104, and critical surfaces throughout the filling process. The sterilization enclosure 180 may provide a controlled environment for a clean/sterilized area within the sterilization enclosure 180. The sterilization enclosure 180 maintains sterility from the unclean/unsterilized area outside of the sterilization enclosure 180. The sterilization enclosure 180 may be one of many different structures known and used in the art. For example, the sterilization enclosure 180 may be a cabinet surrounding the clean equipment and sealed to prevent any outside contaminants. Additionally, within the sterilization enclosure 180, a HEPA air filter 182 may be included to help ensure clean and sterilized controlled air within the sterilization enclosure 180. The HEPA air filter 182 may provide positive pressure and proper flow regimes to help maintain sterility of the bottles 102, caps 104, product, and critical surfaces.
The operation of the sterilization system 100 as illustrated in FIG. 1A may be accomplished in many different methods. For example, first, the system 100 may be pre-sterilized before the initiation of production. Electrolyzed water from an electrolyzed water generator 110 may be used for the sterilization of critical surfaces on the system 100 by spraying electrolyzed water on the critical surfaces and throughout the system 100 within the sterilization enclosure 180.
After the system 100 and critical surfaces are pre-sterilized, the bottles 102 may be loaded into the bottle loader 122. The bottles 102 may be loaded into the bottle loader 122 automatically by mechanical systems or manually by operators. The bottles 102 will then be transported via the bottle conveyor 124 to the bottle rinser 126. During this transport, the bottles 102 may move along the bottle conveyor 124 from the unsterilized or unclean non-aseptic area into the sterilization enclosure 180 to the sterilized/clean aseptic area.
Once the bottles 102 reach the bottle rinser 126, the bottles 102 may be loaded onto the bottle rinser conveyor 130. The bottles 102 may enter the bottle enclosure 134 where the bottles 102 will be sprayed with electrolyzed water. Additionally, the bottle rinser conveyor 130 may invert the bottles 102, so that the openings of the bottles 102 are facing downwardly or to the side. After the bottle rinser conveyor 130 inverts the bottles 102, the bottle spray device 128 may spray electrolyzed water on the bottles 102 as described above. Following the spraying of the bottles 102, the bottle rinser conveyer 130 may then invert the bottles 102 to an upright position with the opening facing upward. The bottles 102 will then be loaded back onto the bottle conveyor 124 and transported to the filler station 160.
Additionally, and concurrently to the bottle operation described above, the caps 104 may be loaded into the cap loader 142. Similarly, the caps 104 may be loaded automatically into the cap loader 142 by mechanical systems or manually by operators. The caps 104 may be transported via the cap conveyor 144 to the cap rinser 146. During this transport, the caps 104 may move along the cap conveyor 144 from the unsterilized or unclean non-aseptic area into the sterilization enclosure 180 to the sterilized/clean aseptic area.
Once the caps 104 reach the cap rinser 146, the caps 104 may be loaded onto the cap rinser conveyor 150. The caps 104 may enter the cap enclosure 154 where the caps 104 will be sprayed with electrolyzed water. Additionally, the cap rinser conveyor 150 may invert the caps 104, so that the caps 104 are facing downwardly. After the caps 104 have been inverted, the cap spray device 148 may spray electrolyzed water on the caps 104 as described above. Following the spraying of the caps 104, the cap rinser conveyer 150 may then invert the caps 104 to an upright position with the opening facing upward. The caps 104 will then be loaded back onto the cap conveyor 144 and transported to the filler station 160.
As the bottles 102 reach the filler station 160, the bottles 102 are loaded onto the filler 162 from the bottle conveyor 124. Each of the bottles 102 are then connected to, associated with, attached to, etc. one of the filling heads 168 of the filler 162. The filler spraying device 170 may spray electrolyzed water on the bottles 102 as they are being connected to the filling heads 168. After the bottles 102 are connected to the filling heads 168, the sterile air blower 174 may provide a light blow of sterile air onto the bottle area to remove any residual electrolyzed water. As the bottles 102 rotate around the filler 162, the bottles 102 are filled with a beverage. After the bottles 102 have been filled to the appropriate volume, one of the caps 104 from the cap conveyor 144 is placed on each of the bottles 102. Similar to the filling process, the filler spraying device 170 may spray electrolyzed water on the bottle/cap area as the caps 104 are placed onto the bottles 102. Following the capping process, the sterile air blower 174 may provide a blow of pressurized sterile air onto the bottle/cap area to remove any residual electrolyzed water. The filled and capped bottles 102 may then be transferred from the filler 162 to the filler conveyor 164 where the filled and capped bottles 102 will be transported from the filler 162 to a location where the bottles 102 can be packed and prepared for shipping.
FIG. 5 illustrates a sterilization system 200 similar to the sterilization system 100 illustrated in FIGS. 1A through 1D and explained above. The sterilization system 200 includes a bottle station 220, a cap station 240, and a filler station 260 similar to the sterilization system 100 in FIGS. 1A through 1D. However, instead of a linear bottle rinser 126 as illustrated in FIG. 1B, the bottle rinser 226 depicted in FIG. 5 is a rotary bottle rinser. The bottle rinser 226 may include at least one bottle spray device 228. Generally, the bottle rinser 226 may spray or dispense electrolyzed water on the bottles 102 as they pass through a given location on the rotary bottle rinser 226. The bottle rinser 226 may include one or more nozzles 232 to spray electrolyzed water onto the bottles 102. Specifically, the nozzles 232 spray a pre-set amount of electrolyzed water on the bottles 102. The bottle spray device 226 may be connected or associated with an electrolyzed water generator 210. In one embodiment of the invention, the nozzles 232 may spray electrolyzed water at a low concentration, low temperature, and a high dwell time. For example, the nozzles 232 may spray electrolyzed water at a concentration range of approximately 50 to 100 PPM as measured as free chlorine, a temperature range of approximately 10 to 30 degrees Celsius, and a time range of approximately 5 to 30 minutes dwell time. In one embodiment of the invention, the nozzles 232 may spray electrolyzed water at a high concentration, high temperature, and a low dwell time. For example, the nozzles 232 may spray electrolyzed water at a concentration range of approximately 100 to 1000 PPM as measured as free chlorine, a temperature range of approximately 25 to 60 degrees Celsius, and a time range of approximately 5 to 30 seconds dwell time.
The rotary bottle rinser 226 may be inline with the other conveyors leading to the filler station 260. Additionally, the rotary bottle rinser 226 may be configured to invert the position of the bottles 102, so that the opening of the bottles 102 are downwardly or side facing when the bottles 102 pass by the bottle spray device 228. Once the bottles 102 are sprayed with electrolyzed water, the rotary bottle rinser 226 may then again invert the position of the bottles 102 to an upright position with the opening facing upwardly.
In another embodiment without departing from this invention, as illustrated in FIG. 6, the sterilization system 300 may include a bottle station 320, a cap station 340, a filler station 360, and a sterilization enclosure 380. The bottle station 320 may include a mechanical fog generator 332 instead of the nozzles as depicted in FIGS. 1A through 1D. The mechanical fog generator 332 may be connected to an electrolyzed water generator 310. The mechanical fog generator 332 may produce small droplets or a fog of electrolyzed water that is dispersed throughout the sterilization enclosure 380. The fog of electrolyzed water may sterilize the bottles 102 using electrolyzed water at a concentration range of approximately 50 to 1000 PPM as measured as free chlorine and a temperature range of approximately 10 to 65 degrees Celsius.
As was described above, a bottle conveyor 324 may be configured to invert the position of the bottles 102, so that the opening of the bottles 102 are downwardly or side facing when the bottles 102 pass through the electrolyzed water fog. After the bottles 102 have been sufficiently fogged, the bottle conveyor 324 may again invert the position of the bottles 102 to an upright position with the opening facing upwardly.
Additionally, the fog of electrolyzed water may be dispersed within a bottle enclosure 334. As was described above, the bottle enclosure 334 may be used to contain the electrolyzed water fog. The bottle enclosure 334 may include panels that surround an area around or associated with the area around the mechanical fog generator 332 and the bottle conveyor 324. The bottle enclosure 334 may also be a cabinet surrounding the fogging area on the bottles 102.
During the fogging of the bottles 102 with electrolyzed water fog, the bottles 102 may contain a small residue of the electrolyzed water that may remain after the sterilization of the bottles 102. The electrolyzed water inside the bottles 102 is not an adulteration issue or product safety issue. In many cases, there is no significant sensory impact. However, to help remove this residue of electrolyzed water, a sterile air blower 336 may be included without departing from the invention. The sterile air blower 336 may provide a pressurized blow of sterile air inside the bottles 102 when the bottle is inverted with the opening facing downward or with the bottle upright with the opening facing upward. This blow of sterile air may be sufficient to remove the majority of residual electrolyzed water.
As further illustrated in FIG. 6, the capping station 340 may include a mechanical fog generator 352 instead of the nozzles as depicted in FIG. 1. The mechanical fog generator 352 may be connected to an electrolyzed water generator 310. The mechanical fog generator 352 may produce small droplets or a fog of electrolyzed water that is dispersed throughout the sterilization enclosure 380. The fog of electrolyzed water may sterilize the caps 104 using electrolyzed water at a concentration range of approximately 50 to 1000 PPM as measured as free chlorine and a temperature range of approximately 10 to 65 degrees Celsius.
As was described above, a cap conveyor 344 may be configured to invert the position of the caps 104, so that the caps 104 are downwardly or side facing when the caps 104 pass through the electrolyzed water fog. After the caps 104 have been sufficiently fogged, the cap conveyor 344 may again invert the position of the caps 104 to an upright position with the cap facing upwardly.
Additionally, the fog of electrolyzed water may be dispersed within a cap enclosure 354. As was described above, the cap enclosure 354 may be used to contain the electrolyzed water fog. The cap enclosure 354 may include panels that surround an area around or associated with the area around the mechanical fog generator 352 and the cap conveyor 344. The cap enclosure 354 may also be a cabinet surrounding the fogging area on the caps 104.
During the fogging of the caps 104 with electrolyzed water fog, the caps 104 may contain a small residue of the electrolyzed water that may remain after the sterilization of the caps 104. The electrolyzed water inside the caps 104 is not an adulteration issue or product safety issue. In many cases, there is no significant sensory impact. However, to help remove this residue of electrolyzed water, a sterile air blower 356 may be included without departing from the invention. The sterile air blower 356 may provide a pressurized blow of sterile air on or inside the caps 104 when the cap is inverted with the opening facing downward or with the cap upright with the opening facing upward. This blow of sterile air may be sufficient to remove the majority of residual electrolyzed water.
In another embodiment without departing from this invention, the mechanical fog generators 332, 352 for the bottles 102 and the caps 104 as illustrated in FIG. 6 may be replaced by electrostatically charged fog generators. In this embodiment, the fog generator produces an electrostatic-positively charged fog of electrolyzed water. Additionally, the bottles 102, the caps 104, and the critical surfaces may be negatively charged or grounded, thereby attracting the electrostatic-positively charged fog of electrolyzed water. The bottles 102, the caps 104, and the critical surfaces may act as a magnet attracting the electrostatic-positively charged fog of electrolyzed water to help sterilize the bottles 102, the caps 104, and the critical surfaces.
FIG. 7 illustrates another embodiment of a sterilization system 400 used to achieve sterile beverages and sterilize bottles 102, caps 104, and critical surfaces. The bottles 102 may contain the sterile beverage and the caps 104 may cover the bottles 102. The sterilization system 400 may include a bottle station 420, a cap station 440, a filler station 460, and a sterilization enclosure 480. The sterilization system 400 may utilize electrolyzed water generated by an electrolyzed water generator 410 to sterilize the bottles 102, the caps 104, and the critical surfaces.
As illustrated in FIG. 7, the sterilization system 400 may include a bottle station 420. The bottle station 420 may include a bottle loader 422 and a bottle conveyor(s) 424. The bottle loader 422 may include a container that holds fully formed unsterilized or unsanitized empty bottles 102. Additionally, the bottle loader 422 may include a device (not shown) within the container to automatically load the bottles 102 on to the bottle conveyor 424. An exemplary configuration of the bottle station 420 is illustrated in FIG. 7. The bottle station 420 may be other types and/or configurations of bottle stations without departing from this invention.
Additionally, as illustrated in FIG. 7, the sterilization system 400 may include a cap station 440. The cap station 440 may include a cap loader 442 and a cap conveyor(s) 444. The cap loader 442 may include a container that holds unsterilized or unsanitized caps 104. Additionally, the cap loader 442 may include a device (not shown) within the container to automatically load the caps 104 on to the cap conveyor 444. An exemplary configuration of the cap station 440 is illustrated in FIG. 7. The cap station 440 may be other types and/or configurations of cap stations without departing from this invention.
Additionally, as illustrated in FIG. 7, the sterilization system 400 may include a filler station 460. The filler station 460 may consist of a filler 462 and a filler conveyor system 464. The filler 462 may be a rotary filler. Additionally, the filler 462 may be other types and configurations of filling systems without departing from this invention. The filler 462 may receive the bottles 102 from the bottle conveyor 424 and fill the bottles 102 with a beverage. Also, the filler 462 may receive the caps 104 from the cap conveyor 444 and place the caps 104 on the bottles 102 after the bottles 102 have been filled. Additionally, there may be a cap tightening device 466 on the filler 462 to ensure the caps 104 are sealed to the bottles 102. The filler 462 may perform other operations without departing from this invention, such as placing a seal on the bottle after filling and prior to placing the caps 104 on the bottles 102. The filler station 460 may also include a filler conveyor system 464 which transports the filled and capped bottles 102 from the filler 462 to a location where the bottles 102 can be packed and prepared for shipping.
Additionally, as illustrated in FIG. 7, the sterilization system 400 may include a sterilization enclosure 480. This sterilization enclosure 480 may maintain aseptic conditions for the bottles 102, caps 104, and critical surfaces throughout the filling process. The sterilization enclosure 480 may provide a controlled environment for the clean/sterilized area inside the sterilization enclosure 480. The sterilization enclosure 480 maintains sterility from the unclean/unsterilized area outside of the sterilization enclosure 480. The sterilization enclosure 480 may be one of many different structures known and used in the art. For example, the sterilization enclosure 480 may be a cabinet surrounding the clean equipment and sealed to prevent any outside contaminants.
In an embodiment of this invention, electrolyzed water may be used to pre-sterilize the system 400 before the initiation of production and prior to loading and filling the bottles 102 and caps 104. Additionally, electrolyzed water may be used to sterilize the system 400 if sterility is lost, such as for equipment maintenance or component problems which require intervention by an operator or technician. For example, electrolyzed water may be used for the sterilization of critical surfaces on the system 400. Critical surfaces may include surfaces or equipment on the filler 462, such as a filling chamber (the internal chamber of the filler 462), the filler heads 468 (which connect or associate with the bottles 102 to fill the bottles 102 with beverage), the cap tightening device 466 (which tightens the caps 104 onto the bottles 102), or any other surfaces that may contact the areas on the bottles 102 or the caps 104 that may come in contact with the beverage. At least one mechanical fog generator 472 connected to an electrolyzed water generator 410 may be utilized to provide an electrolyzed water fog that performs the pre-sterilization functions.
Additionally, electrolyzed water may be used to help maintain sterility of the system 400 and critical surfaces during the filling process. For example, the mechanical fog generator 472 may be connected to an electrolyzed water generator 410. The mechanical fog generator 472 may produce small droplets or a fog of electrolyzed water that is dispersed throughout the sterilization enclosure 480. The fog of electrolyzed water may sterilize and maintain sterility of the bottles 102, caps 104, and critical surfaces using electrolyzed water at a concentration range of approximately 50 to 1000 PPM as measured as free chlorine and a temperature range of approximately 10 to 65 degrees Celsius. As was discussed above, the electrolyzed water does not provide a product adulteration issue and there may be no significant sensory impact.
The operation of the sterilization system 400 as illustrated in FIG. 7 may be accomplished in many different methods. For example, first, the sterilization system 400 may be pre-sterilized before the initiation of production. Electrolyzed water may be used for the sterilization of critical surfaces on the system by fogging the system 400 and the critical surfaces with electrolyzed water within the sterilization enclosure 480.
After the system 400 and critical surfaces are pre-sterilized, the bottles 102 may be loaded into the bottle loader 422. The bottles 102 may be loaded into the bottle loader 422 automatically by mechanical systems or manually by operators. The bottles 102 will then be transported via the bottle conveyor 424 to the filler station 460. During this transport, the bottles 102 may move along the bottle conveyor 424 into the sterilization enclosure 480.
Additionally, and concurrently to the bottle operation described above, the caps 104 may be loaded into the cap loader 442. Similarly, the caps 104 may be loaded automatically into the cap loader 442 by mechanical systems or manually by operators. The caps 104 may be transported via the cap conveyor 444 to the filler station 460. During this transport, the caps 104 may move along the cap conveyor 444 into the sterilization enclosure 480.
As the bottles 102 and caps 104 move into the sterilization enclosure 480, the electrolyzed water fog produced by the electrolyzed water fog generator 472 sterilizes the bottles 102 and the caps 104. As the bottles 102 reach the filler, the bottles 102 are loaded into the filler 462 from the bottle conveyor 424. Each of the bottles 102 are then connected to, associated with, attached to, etc. one of the filling heads 468 of the filler 462. As the bottles 102 rotate around the filler 462, the bottles 102 are filled with a beverage. After the bottles 102 have been filled to the appropriate volume, one of the caps 104 from the cap conveyor 444 is placed on the bottle. Throughout the filling and capping process, the electrolyzed water fog surrounds the process and maintains sterility of the system. The filled and capped bottles 102 may then be transferred from the filler 462 to the filler conveyor 464 where the filled and capped bottles 102 will be transported from the filler 462 to a location where the bottles 102 can be packed and prepared for shipping.
In another embodiment, the mechanical fog generators 472 illustrated in FIG. 7 may be replaced by an electrostatically charged fog generator as was described above. In this embodiment, the fog generator produces an electrostatic positively-charged fog of electrolyzed water. Additionally, the bottles 102, the caps 104, and the critical surfaces may be negatively charged or grounded, thereby attracting the electrostatic positively-charged fog of electrolyzed water. The bottles 102, the caps 104, and the critical surfaces act as a magnet attracting the electrostatic positively-charged fog of electrolyzed water to help sterilize and maintain sterility of the bottles 102, the caps 104, and the critical surfaces.
FIG. 8 illustrates yet another embodiment of a portion of a sterilization system that includes an isolator 590 around the critical surfaces of the filler 562. In this embodiment, the isolator 590 surrounds and provides a controlled environment for the area surrounding the critical surfaces on the filler 562. The isolator 590 may be one of many different structures known and used in the art. For example, the isolator 590 may be a cabinet that surrounds the critical surfaces and is sealed to prevent any outside contaminants. Additionally, any of the above described methods for pre-sterilization and maintenance of sterility may be used with the isolator 590 and the sterilization/maintenance of sterility of the critical surfaces. For example, the pre-sterilization and maintenance of sterility may be provided by an electrolyzed water generator 510 that provides: 1) intermittent spray of electrolyzed water from filler nozzles 572 on the critical surfaces within the isolator 590; 2) a mechanical fog generator 573 connected to an electrolyzed water source 510 to provide a fog of electrolyzed water throughout the isolator 590; and 3) an electrostatic fog generator connected to an electrolyzed water source to provide an electrostatic positively-charged fog throughout the isolator 590, or any combination thereof. In this embodiment, the bottles 102 and/or the caps 104 may be sterilized prior to reaching the isolator 590. Additionally, the bottles 102 and/or the caps 104 may not be sterilized prior to reaching the isolator 590, and the means described above, intermittent spray, mechanical fog, or electrostatically charged fog, may be utilized to sterilize the bottles 102 and/or the caps 104 within the isolator 590.
In another embodiment similar to the embodiment illustrated in FIG. 8, the sterilization system may include one or multiple small chambers or enclosures instead of the entire isolator. One or multiple small chambers may surround or enclose the critical surfaces or critical path areas identified above, such as the area surrounding the filler heads that connect to or associate with the bottles 102 to fill the bottles 102 with the beverage, or the area surrounding the cap tightening device that seals the bottles 102 and tightens the caps 104 onto the bottles 102. These small chambers or enclosures need not be fully enclosed around the area. The small chambers or enclosures may provide positive air flow protection to maintain sterility or sanitization at those critical surfaces and areas, such as with HEPA filtered air or an electrolyzed fog within the small chamber or enclosure.
The various embodiments of the invention described and illustrated with reference to FIGS. 1A-8 provide several benefits and advantages. First, the safety and health efficacy of electrolyzed water is improved as compared to the use of other sterilizing agents used in the prior art. Electrolyzed water is considered a very benign chemical as compared to other sterilizing agents used in the prior art. Additionally, there are no food adulteration problems, thereby minimizing any possible consumer issues. Second, this sterilization system can sterilize at a high speed under a set of conditions, thereby increasing the output of the production system. Third, the electrolyzed water can be produced on-site and as needed. Other chemicals and sterilizing agents need to be ordered and delivered to the production facility. Fourth, there is no rinse step needed when using electrolyzed water which reduces water resources. The rinse step required for other sterilizing agents adds increased equipment costs, increased production time, and increased water (for the rinse) usage. Fifth, during changeovers or maintenance work, the pre-sterilization step with electrolyzed water is a shorter time requirement than is needed for chemical and other sterilization agent change-overs and maintenance work. Additionally, the use of electrolyzed water for sterilization allows the use of light weight bottles. The embodiments of the invention of this sterilization system can be easily retrofitted with existing hot fill sterilization systems.
The invention herein has been described and illustrated with reference to the embodiments of FIGS. 1A-8, but it should be understood that the features of the invention are susceptible to modification, alteration, changes or substitution without departing significantly from the spirit of the invention. For example, the dimensions, size and shape of the various bottles, caps, conveyors, and other equipment or components may be altered to fit specific applications. Accordingly, the specific embodiments illustrated and described herein are for illustrative purposes only and the invention is not limited except by the following claims and their equivalents.

Claims

1. A sterilization system used to achieve sterile beverages and sterilize bottles and caps, wherein the bottles contain the sterile beverage and the caps cover the bottles, the sterilization system comprising:

a bottle sterilizer for sterilizing the bottles, wherein the bottle sterilizer discharges electrolyzed water onto the bottles;

a cap sterilizer for sterilizing the caps, wherein the cap sterilizer discharges electrolyzed water onto the caps; and

a filler station that includes a filler sterilizer and a filler that includes product-contact surfaces, wherein the filler fills the bottles with the beverage and caps the bottles, wherein the filler sterilizer sterilizes the filler station before the initiation of production by discharging electrolyzed water on the product-contact surfaces.

2. The sterilization system according to claim 1, wherein the bottle sterilizer, the cap sterilizer, and the filler sterilizer include a mechanical sprayer that includes nozzles that discharge a spray of electrolyzed water onto the bottles, the caps, and the product-contact surfaces respectively.

3. The sterilization system according to claim 2, wherein the spray of electrolyzed water is at a concentration range of approximately 50 to 100 PPM as measured as free chlorine, a temperature range of approximately 10 to 30 degrees Celsius, and a hold time range of approximately 5 to 30 minutes.

4. The sterilization system according to claim 2, wherein the spray of electrolyzed water is at a concentration range of approximately 100 to 1000 PPM as measured as free chlorine, a temperature range of approximately 25 to 65 degrees Celsius, and a hold time range of approximately 5 to 30 seconds.

5. The sterilization system according to claim 1, wherein the bottle sterilizer, the cap sterilizer, and the filler sterilizer include a fog generator that discharges a fog of electrolyzed water onto the bottles, the caps, and the product-contact surfaces respectively.

6. The sterilization system according to claim 5, wherein the fog of electrolyzed water is discharged at a concentration range of approximately 50 to 100 PPM as measured as free chlorine and a temperature range of approximately 10 to 30 degrees Celsius.

7. The sterilization system according to claim 5, wherein the fog of electrolyzed water is discharged at a concentration range or approximately 100 to 1000 PPM as measured as free chlorine and a temperature range of approximately 25 to 65 degrees Celsius.

8. The sterilization system according to claim 1, wherein the bottle sterilizer, the cap sterilizer, and the filler sterilizer include an electrostatic fog generator that discharges an electrostatically charged fog of electrolyzed water onto the bottles, the caps, and the product-contact surfaces respectively.

9. The sterilization system according to claim 8, wherein the electrostatically charged fog of electrolyzed water is at a concentration range of approximately 50 to 100 PPM as measured as free chlorine and a temperature range of approximately 10 to 30 degrees Celsius.

10. The sterilization system according to claim 8, wherein the electro-statically charged fog of electrolyzed water is at a concentration range of approximately 100 to 1000 PPM as measured as free chlorine and a temperature range of approximately 25 to 65 degrees Celsius.

11. The sterilization system according to claim 1, wherein the electrolyzed water is produced by passing water through an electrochemical cell which results in two separate electrically opposite streams, a first stream that has a disinfectant property and includes a positively charged stream with a pH between approximately 6-8, and a second stream that has a detergent property and includes a negatively charged stream with a pH between approximately 11 and 13.

12. A sterilization system used to achieve sterile beverages and sterilize bottles and caps, wherein the bottles contain the sterile beverage and the caps cover the bottles, the sterilization system comprising:

an electrolyzed water generator that produces electrolyzed water;

a bottle station for sterilizing the bottles, the bottle station including a bottle loader for loading the bottles, a bottle conveyor for transporting the bottles, and a bottle rinser located along the bottle conveyor and connected to the electrolyzed water generator, wherein the bottle rinser sprays the electrolyzed water onto the bottles;

a cap station for sterilizing the caps, the cap station including a cap loader for loading the caps, a cap conveyor for transporting the caps, and a cap rinser located along the cap conveyor and connected to the electrolyzed water generator, wherein the cap rinser sprays the electrolyzed water on the caps;

a filler station connected to the bottle station and the cap station, wherein the filler station includes a filler with critical surfaces that are potential product-contact surfaces during the filling operation, and wherein the filler fills the bottles with the beverage and caps the bottles after the bottles are filled with the beverage, and wherein the filler station further includes a spray device connected to the electrolyzed water generator that sprays the electrolyzed water onto the critical surfaces of the filler.

13. The sterilization system according to claim 12, wherein the critical surfaces include one or more of the following: internal chamber of the filler, filler heads that connect to or associate with the bottles to fill the bottles with the beverage, or a cap tightening device that tightens the caps onto the bottles.

14. The sterilization system according to claim 12, wherein the electrolyzed water is sprayed at a concentration range of approximately 50 to 100 PPM as measured as free chlorine, a low temperature range of approximately 10 to 30 degrees Celsius, and a dwell time range of approximately 5 to 30 minutes.

15. The sterilization system according to claim 12, wherein the electrolyzed water is sprayed at a concentration range of approximately 100 to 1000 PPM as measured as free chlorine, a temperature range of approximately 25 to 65 degrees Celsius, and a dwell time range of approximately 5 to 30 seconds.

16. The sterilization system according to claim 12, further comprising a sterilization enclosure that fully encloses the filler, wherein the sterilization enclosure maintains aseptic conditions for the bottles, the caps, and the critical surfaces.

17. The sterilization system according to claim 16, wherein the sterilization enclosure includes a HEPA air filter to provide positive air pressure and proper air flow regimes throughout the sterilization enclosure.

18. A sterilization system used to achieve sterile beverages and sterilize bottles and caps, wherein the bottles contain the sterile beverage and the caps cover the bottles, the sterilization system comprising:

a bottle station that includes a bottle loader for loading the bottles and a bottle conveyor for transporting the bottles;

a cap station that a cap loader for loading the caps and a cap conveyor for transporting the caps;

a filler station connected to the bottle station and the cap station, wherein the filler station includes a filler with critical surfaces that are potential product-contact surfaces during the filling operation, and wherein the filler fills the bottles with the beverage and caps the bottles after the bottles are filled with the beverage;

a sterilization enclosure that fully encloses the filler, wherein the sterilization enclosure maintains aseptic conditions for the bottles, the caps, and the critical surfaces;

an electrolyzed water generator that produces electrolyzed water;

a fog generator connected to the electrolyzed water generator, wherein the fog generator produces a fog of electrolyzed water that is dispersed within the sterilization enclosure, wherein the fog of electrolyzed water sterilizes the bottles, caps, and critical surfaces.

19. The sterilization system according to claim 18, wherein the critical surfaces include one or more of the following: internal chamber of the filler, filler heads that connect to or associate with the bottles to fill the bottles with the beverage, or a cap tightening device that tightens the caps onto the bottles.

20. The sterilization system according to claim 18, wherein the electrolyzed water generator produces electrolyzed water at a concentration range of approximately 50 to 1000 PPM as measured as free chlorine.

21. The sterilization system according to claim 18, wherein the fog generator produces an electrostatic, positively-charged fog of electrolyzed water.

22. The sterilization system according to claim 21, wherein the bottles, the caps, and the critical surfaces are negatively charged or grounded, wherein the bottles, the caps, and the critical surfaces attract the electrostatic, positively-charged fog of electrolyzed water, thereby sterilizing the bottles, the caps, and the critical surfaces.

23. A method for achieving sterile beverages and sterilizing bottles and caps comprising:

sterilizing the bottles by using electrolyzed water on the bottles;

sterilizing the caps by using electrolyzed water on the caps; and

sterilizing a filler with electrolyzed water before the initiation of production.