WO2000041965A1

WO2000041965A1 - Method for rinsing a fluid transfer system

Info

Publication number: WO2000041965A1
Application number: PCT/US2000/000910
Authority: WO
Inventors: Robert Kiholm
Original assignee: Kiholm Industries Llc
Priority date: 1999-01-14
Filing date: 2000-01-13
Publication date: 2000-07-20
Also published as: CA2360263A1; US6158481A; US6098672A; AU2726400A

Abstract

A method and apparatus are provided for recovering a product from a filling line being used to fill containers with the product. The filling line comprises at least a filler, a pump, a check valve, compressed air/gas, a water source, and a holding tank containing the product, all interconnected by a product line. In the method, the filling line is rinsed, and the rinse water is then evacuated from the filling line using compressed air/gas. Next, using a pump, the product is transferred from the holding tank through the filler line to the filler, and then into containers. The transfer continues until the pump is no longer primed with the product. The remaining product is then pushed with the compressed air/gas through the filler line into the filler and then into containers, thereby recovering substantially all the product remaining in the filler line. The product recovery method minimizes the amount of waste product that must be discarded from a bottling line.

Description

Title: METHOD FOR RINSING A FLUID TRANSFER SYSTEM

TECHNICAL FIELD

This invention relates to the field of product recovery in filling lines used to fill containers,

including bottling lines and can lines used to fill containers in the food, beverage, and

pharmaceutical industries. BACKGROUND OF THE INVENTION

The bottling and canning industry is devoted to filling containers with a tremendous

variety of products. These products vary in terms of their viscosity, ranging from high viscosity

products such as peanut butter, salad dressings, and frozen concentrated juices; medium viscosity

products, such as pharmaceutical syrups, soups, stews, and sauces; to low viscosity products such

as wine and juices. These products also vary in terms of their properties, one the most notable

of which is the presence of absence of carbonation. Champagne, beer, and soda pop beverages

are all good examples of either naturally or artificially carbonated beverages.

The bottling line designs presently used are burdened with serious problems in the area

of product recovery. The "product recovery problem" means that periodically a significant

quantity of product in the bottling line becomes waste that cannot be economically recovered for

later use. The product recovery problem typically arises in several situations with present

bottling line designs. For example, because of the current design of bottling lines, if a bottling line

is used to fill containers with a variety of different products over the course of a day or a week,

then each time a bottling run for one product ends and a bottling run for a different product

begins, a considerable amount of both products becomes unrecoverable waste. Current bottling line designs also cause a considerable amount of perishable products, or products requiring special

handling to ensure product integrity or purity (such as carbonated products which must be

maintained at a constant temperature during the bottling process), to become unrecoverable waste

at the end of each work day, or bottling run, or product change.

It is a regrettable fact that much of the unrecoverable product waste currently created by the bottling industry is often literally dumped down the drain, or is stored in drums to later be

taken to a landfill, or, for certain potentially hazardous products, to an appropriate hazardous

waste disposal facility. In the case of food and beverage products, this unrecoverable waste is

most often dumped down the drain. The "drain dumping" disposal method costs the bottler more

than just the value of the wasted product, because this wasted product must be treated before it

is reintroduced back into the environment.

For those bottling companies without their own waste water treatment facility, the waste

product dumped into the drain travels through the sewage system to the local sewage treatment facility. The high sugar content of most wasted products then causes a population explosion in

the bacteria at the sewage treatment facility. The bacteria used by sewage treatment facilities is

"aerobic" bacteria, which means they use up oxygen as they consume sewage waste. Sewage

treatment plants maintain a careful balance between their bacteria's population and the incoming

sewage waste, to ensure adequate oxygen for their bacteria to survive. Sewage treatment plants

make every effort to ensure that their entire system remains aerobic (with oxygen) rather than

anaerobic (without oxygen). Aerobic bacteria do not create offensive odors when they consume

sewage waste. Anaerobic bacteria create offensive odors, and are less efficient than aerobic

bacteria at disposing of sewage waste. Sewage treatment plants track precisely how much high

sugar content industrial waste is dumped into their system, and they charge each company dumping this waste a Biological Oxygen Demand (BOD) assessment. Presently, the BOD assessment for many bottling plants ranges from $25,000 to $100,000 per month.

Sewage treatment plants also track precisely the quantity of suspended solids contained

in the waste stream they receive from industrial sources, because the required treatment of these

suspended solids is expensive. Suspended solids are present in unfiltered fruit juices, soups, sauces, peanut butter, condiments, and a wide variety of other products. In addition to a monthly

B . O.D. assessment, sewage treatment plants also charge their industrial sewage sources a monthly

suspended solids assessment. Presently, the suspended solids assessment for many bottling and canning plants ranges from $25,000 to $250,000 per month.

For those bottling companies that elect to build their own waste water treatment facility,

they must incur the expense of building, maintaining, and operating their own facility. This cost,

which can be considerable, is often incurred primarily because of their decision to dump wasted

product down the drain.

The magnitude of the product recovery problem is surprisingly large. On a daily basis,

many bottling companies are dumping 500 to 2500 gallons of wasted product down the drain, or

into drums for landfill disposal, for each bottling line they operate. Many bottling companies

operate multiple bottling lines in each of their bottling plants. Accordingly, there is a great need

for a solution to the problem of product recovery. Such a solution must maintain product

integrity and product purity throughout the entire recovery process.

SUMMARY OF INVENTION

This invention provides a method and apparatus for recovering a product from a filling

line being used to fill containers with the product. The filling line comprises at least a filler, a

pump, a check valve, compressed air/gas, a water source, and a holding tank containing the product, all interconnected by a product line. In the method, the filling line is rinsed, and the rinse

water is then evacuated from the filling line using compressed air/gas. Next, using a pump,

the product is transferred from the holding tank through the filler line to the filler, and then into

containers. The transfer continues until the pump is no longer primed with the product. The

remaining product is then pushed with the compressed air/gas through the filler line into the filler

and then into containers, thereby recovering substantially all the product remaining in the filler line.

In an additional embodiment, the invention provides a method and apparatus for

recovering a product during the transfer of the product between a tanker truck and a tank.

In yet a further embodiment, the invention provides a method and apparatus for recovering

a product during the transfer of the product between the holding tank and a receiving tank.

In yet a further embodiment, the invention provides a method and apparatus for

maintaining the product at a desired temperature while substantially all of the product is recovered from the filling line.

The invention has the advantage of providing a method and apparatus for product

recovery which minimizes the amount of waste product that must be discarded from a bottling

line when the line is shut down, or a change is made from one product to another.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic flow diagram of a preferred embodiment of the present invention

showing a method and apparatus for the recovery of product during the transfer of product from

a tanker truck to a tank;

FIG. 1 A shows the relationship between FIGS. 1 and 2; FIG. 2 is a schematic flow diagram of a preferred embodiment of the present invention

one tank to another tank;

FIG. 2 A shows the relationship between FIGS. 2 and 4;

FIG. 2B shows the relationship between FIGS. 2 and 5;

FIG. 2C shows the relationship between FIGS. 2 and 6;

FIG. 2D shows the relationship between FIGS. 2 and 7;

FIG. 3is a schematic flow diagram of a preferred embodiment of the present invention

showing a method and apparatus used for a product recovery module used in tank-to-tank

product recovery, as shown in FIG. 2;

FIG. 4 is a schematic flow diagram of a preferred embodiment of the present invention

showing a product recovery system which maintains substantially all of the product at a desired

temperature during the entire product recovery process;

FIG. 5 is a schematic flow diagram of a preferred embodiment of the present invention

temperature during the entire product recovery process;

FIG. 6 is a schematic flow diagram of a preferred embodiment of the present invention

temperature during the entire product recovery process; and

FIG. 7 is a schematic flow diagram of a preferred embodiment of the present invention

temperature during the entire product recovery process.

DETAD ED DESCRIPTION OF SPECIFIC EMBODIMENTS I. TRUCK-TO-TANK PRODUCT RECOVERY

Container filling facilities, such as bottling plants, fill containers with a wide variety of

products, such as juice, juice concentrate, carbonated beverages, wine, beer, liquid medicines, and

motor oil - to name a few. The product is often transported to a container filling facility by a

tanker truck in liquid form, either as a concentrate, or as ready-to-use product. In that event, the

following method and apparatus depicted in FIG. 1 can be used to recover substantially all of the product from the tanker truck for storage in a tank for later use.

A. INITIAL WATER RINSE PROCEDURE

In order to prepare the system for the transfer of a product from a tanker truck 2 to a tank

such as a bulk receiving storage tank 22 (which functions as a receiving tank for the product), the

first step is to send water 3 through a tanker truck first check valve 6 and then through a flexible

food grade USDA approved hose 8 removably connected at its first end 8a to the tanker truck

first check valve 6 and permanently connected at its second end 8b to a tanker truck pump 10.

The water thus primes pump 10. Activate pump 10, sending water 3 sequentially through a

tanker truck product line 11, a tanker truck second check valve 12, a tanker truck sight glass 14,

and a tanker truck divert valve 16. Divert valve 16 is opened so that water 3 continues through

a bulk receiving tank product intake line 19 to a bulk receiving tank first divert valve 20, and into

a bulk receiving tank 22. Water 3 is preferably pumped through all of this equipment at a flow

rate approximately equivalent to 80 g.p.m. within a schedule 40 steel pipe having a nominal

diameter of 2 inches, for approximately 60 seconds, or as needed to adequately flush and rinse

the equipment. Discontinue the flow of water 3 and allow the water to drain from the lines and

equipment into bulk receiving tank 22. Close the bulk receiving tank first divert valve 20 and bulk receiving tank second divert

valve 26 from its initially closed position. The second divert valve is preferably located at or near

the bottom of the bulk receiving tank. Rinse the bulk receiving tank 22 by spraying bulk receiving

tank spray ball water 24 through a spray ball (not shown) inside of bulk receiving tank 22

preferably for approximately 60 seconds at a flow rate approximately equivalent to 80 g.p.m.

within a schedule 40 steel pipe having a nominal diameter of 2 inches, or as required to adequately

rinse the tank. Then open the second divert valve 26 and allow the water which has accumulated

in the bulk receiving tank to drain into a bulk receiving tank drain 28.

B. RINSE WATER AIR/GAS EVACUATION PROCEDURE

Because the pumps used for tanker truck pump 10 are typically large, twenty or more

gallons of water will often remain after water 3 is allowed to drain from pump 10. To thoroughly

clear the pump 10 of water, send compressed air/gas 5 through first check valve 6 through hose

8 and into and through pump 10, preferably for approximately 10 seconds at a flow rate

approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe having a nominal diameter

of 2 inches, or as required to clear hose 8 and pump 10, and to push any of water 3 remaining in

the product line 11 past the second check valve 12.

Send compressed air/gas 13 through second check valve 12, preferably for approximately

2 minutes at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe

having a nominal diameter of 2 inches, through product line 11, tanker truck sight glass 14, divert

valve 16, bulk receiving tank intake product line 19, first divert valve 20, and bulk receiving tank

22. The actual flow rate and flow duration of the compressed air/gas needed to thoroughly expel

the rinse water from the system is based upon the size and length of tanker truck product line 11

and bulk receiving tank product intake line 19. After the compressed air/gas 13 has expelled all of the remaining water 3 into bulk receiving tank 22, allow all of the accumulated water to drain

completely from the bulk receiving tank 22 through second divert valve 26 opened to drain 28.

C. COMPARISON TO PRIOR ART At this point, prepare to pump the product from tanker truck 2 to the bulk receiving tank

22. Because there is an insignificant amount of water remaining in the system between hose 8 and

bulk receiving tank 22 at this stage of the process, the product from the tanker truck 2 can flow through the system at without any detectable dilution by the rinse water. This is in marked contrast to prior methods and apparatus, which would have rinsed the entire system with water, and then would have used the product flowing from tanker truck 2 to push the rinse water through the system into bulk receiving tank 22. Under the prior approach, a substantial amount

of product would have to run through the entire system before the product flowing through the bulk receiving tank product intake line 19 returned to its undiluted state. Under the prior

approach, the diluted product which had accumulated in the bulk receiving tank 22 would then

be discarded by dumping it into drain 28. In the present invention, the problem of discarding

diluted, unusable product is virtually eliminated, because compressed air/gas 5 and 13 (which is optionally food and drug quality compressed air/gas) is used to evacuate the rinse water prior to

introducing any product into the system.

D. PRODUCT TRANSFER In order to prepare to pump the product from tanker truck 2 to the bulk receiving tank

22, close bulk receiving tank second divert valve 26. Disconnect the first end 8a of flexible hose

8 from first check valve 6 and connect it to a tanker truck valve 4 locate on the tanker truck 2.

Open the tanker truck valve 4, so that product flows into the hose 8, and into the pump 10. Activate pump 10 and pump product from tanker truck 2 to the bulk receiving tank 22, preferably

until tanker truck 2 is empty.

At this point, tanker truck product line 11 and all the equipment it interconnects, and bulk

storage tank product intake 19 and all the equipment it interconnects, are all charged with

undiluted, usable product. With the tanker truck 2 empty, the pump 10, has no more product to

pump, and thus cannot clear the system of product.

E. PRODUCT RECOVERY PROCEDURE

Under the prior approach, before the present invention, the product in the system at this

point would be pushed through the tanker truck product line 11 and the bulk storage tank intake

product line 19 by rinse water, thus diluting a substantial quantity of the remaining product and

rendering it unusable. This diluted product would then be dumped to a drain - a wasteful and

costly approach.

In the present invention, the product left in the tanker truck product line 11 and the bulk

storage tank intake product line 19 is recovered using the air/gas evacuation approach. After the

pump 10 can no longer push any further product down the tanker truck product line 11,

deactivate the pump. Disconnect the first end 8a of the hose 8 from the tanker truck 2, and

connect the first end 8a to the first check valve 6.

As with the rinse water, a significant quantity of product may remain in the pump 10,

because of the typical large size of the pumps used for tanker trucks pump 10. Send compressed

air/gas 5 through the first check valve 6 through hose 8 and into and through pump 10 to clear

hose 8 and pump 10, preferably at a flow rate approximately equivalent to 80 c.f.m. within a

schedule 40 steel pipe having a nominal diameter of 2 inches, for approximately 30 seconds, or as required to in order to push any remaining product in the product line 11 past the second check

valve 12.

Immediately send compressed air/gas 13 through second check valve 12 into the tanker

truck product line 11, the tanker truck sight glass 14, the tanker truck divert valve 16, the bulk

receiving tank intake product line 19, the first divert valve 20, and into bulk receiving tank 22,

preferably for approximately 2 minutes at a flow rate approximately equivalent to 80 c.f.m. within

a schedule 40 steel pipe having a nominal diameter of 2 inches, or as required to expel all of the

product remaining in the lines and equipment into the bulk receiving tank 22. Before turning off

the flow of compressed air /gas 13, utilize sight glass 14, or alternately a suitable automatic sensor

device, to verify that there is no product remaining in the tanker truck product line 11. Then wait

for the compressed air/gas 13 to expel the remaining product in the bulk receiving tank product

intake line 19 into the bulk receiving tank 22. With the compressed air /gas 13 still flowing, turn

off the first divert valve 20, and open the tank truck divert valve 16 to the tanker truck drain 18.

At this point a very small amount of residual product is expelled into the drain 18. Open the first

divert valve 20 to the bulk receiving tank drain 28, and open the tanker truck divert valve 16 to

product intake line 19. The very small amount of remaining product residue will be expelled into

drain 28. Then shut off the flow of compressed air /gas 13. At this point in the process,

substantially all of the product originally carried by tanker truck 2 will have been transferred to

bulk receiving tank in undiluted and usable condition, leaving only an insignificant amount of

product residue behind.

As an alternative, it is optional at this stage of the process to rinse the system again before

using it to transfer a new product to another bulk receiving tank. In the event that the system is not rinsed at this time, it will be rinsed by use of the Initial Water Rinse procedure, described in section LA. above, prior to the transfer of any new product.

In order to accomplish the optional rinse procedure, send water 3 through the first check

valve 6, the hose 8, and into the pump 10. From the pump, water 3 continues through the tanker

truck product line 11 connecting the pump 10, the second check valve 12, the sight glass 14, the

divert valve 16, the product intake line 19, and into the first divert valve 20. At this point in time,

first divert valve 20 remains opened to the drain 28, so that water 3 empties into the drain 28.

Run water 3 through all of this equipment, preferably for approximately 90 seconds at a flow rate

of approximately 80 g.p.m, or as required to adequately rinse the lines and equipment. Shut off

the flow of water 3. The entire system prior to the bulk receiving tank 22 has now been rinsed

clean.

The bulk storage tank 22 now contains substantially all of the product which was delivered

in the tanker truck 2, with no product rendered unusable by dilution, and only an insignificant

amount of the product being discarded.

F. PREFERRED COMPONENTS. In a preferred embodiment of the truck-to-tank recovery system, the following

components have been utilized successfully, although other components which function in an

equivalent manner can also be used:

Water 3 and 15 Approved government standards drinking water or approved process water, meeting FDA standards, is obtained using standard filtration and treatment equipment .

Air/gas 5 and 13 For food and drug related applications of the present invention, Food and Drug Administration (FDA) grade sanitary air is preferably obtained by three stage Filenco

Dryer/Filters to filter and dry high pressure compressed air on a point-of-use basis immediately prior to the introduction of the compressed air/gas to the check valves 6 and 12. Alternately, regular atmosphere air, or any inert or non-reactive gas, if filtered and dried properly, can be used for compressed air/gas 5 and 13 in non-food and non- drug applications of the present invention.

Check Valves 6 and 12 Tri-Clover 316 stainless steel ball check valve with Tri- Clover 316 stainless steel air/gas blow attachment. Hose 8 Goodyear brand Wineline Hose, a food grade USDA approved hose.

Pump 10 Tri Clover 316 stainless steel food grade sanitary pump. Both centrifical and positive displacement type pumps have been successfully utilized.

Product Line 11 316 stainless steel lines, approximately two inches in diameter for this preferred embodiment.

Sight Glass 14 Jensen 316 stainless steel sight glass.

Divert Naive 16 Tri Clover 316 stainless steel pneumatic divert valve or Tri Clover 316 stainless steel 3 way manual valve.

Product Line 19 316 stainless steel lines, approximately two inches in diameter for this preferred embodiment.

Divert Valves 20 and 26 Defonex 316 stainless steel manual butterfly valves.

Bulk Receiving Tank 22 316 stainless steel tank. Tanks manufactured by Mueller Tanks, Feldmeyer, and A.P.N. Crepaco have been successfully utilized.

H. TAΝK-TO-TAΝK PRODUCT RECOVERY

In a container filling facility, many processing steps require the transfer of product from

a tank containing product (functioning as a holding tank) to another tank (functioning as a

receiving tank for the product). The following method and apparatus can be used to recover

substantially all of the product from the lines and equipment used to transfer the product from one

tank to another tank. FIG. 2 depicts the process steps involved in the transfer of product among

a variety of the different tanks which may be found at a typical container filling facility. The tanks

described in FIG. 2, however, are intended to be representative of any tank used to store product, on either a long term and short terms basis. FIG. 3 depicts the process steps involved in actually

recovering product from the lines and equipment used to transfer product from one tank to another.

A. DESCRΠTION OF FIG.2

The overall process of product recovery during tank-to-tank product transfer is described

by the process steps depicted in FIG. 2. The specific process steps embodied in each Product

Recovery Module 200, 216, 232, and 248, and the equipment necessary to effectuate those

process steps, are depicted in FIG. 3, and described below following the description of FIG. 2.

1. Transfer of Product from a Bulk Receiving Tank

To a Bulk Storage Tank

Once the bulk receiving tank 22 as shown in FIG. 1 has been loaded with product the

system is ready to transfer product from the bulk receiving tank 22 to a bulk storage tank 206 as

shown in FIG. 2 (or, alternatively, any other type of tank). Initially, close a bulk storage tank

second divert valve 214, so that no rinse water can escape from the bulk storage tank 206. Then

rinse the product lines and equipment in the bulk receiving tank product recovery module 200,

as well as a bulk storage tank first divert valve 204 and the bulk storage tank 206, all according

to the "Product Recovery Module - Initial Water Rinse Procedure" (FIG. 3, described below in

Section II. B.1), with the bulk storage tank first divert valve 204 open to the bulk storage tank 206

so that rinse water 302 (FIG. 3) will flow into the bulk storage tank 206. Allow the water 302

to accumulate in the bulk storage tank 206.

The second step is to evacuate the rinse water 302 from the product lines and equipment

in bulk receiving tank product recovery module 200, and the first divert valve 204, into the bulk

storage tank 206, using compressed air/gas, all according to the "Product Recovery Module -

Rinse Water Air/Gas Evacuation Procedure" (FIG. 3, described below in Section II.B.2). After substantially all of the rinse water is pushed into the bulk storage tank 206, open the second divert

valve 214 to a bulk storage tank drain 210 and allow the accumulated rinse water to drain away.

The third step is to transfer product from the bulk receiving tank 22, through the bulk

receiving tank product recovery module 200, and into the bulk storage tank 206, all according

to the 'Troduct Recovery Module - Product Transfer Procedure" (FIG. 3, described below in Section II.B.3).

The fourth step is to recover substantially all the remaining product from the bulk

receiving tank 22, bulk receiving tank product recovery module 200, and first divert valve 204,

and expel the recovered product into the bulk storage tank 206, all according to the "Product

Recovery Module Product Recovery Procedure" (FIG. 3, described below in Section II.B.4). At

this stage of the process, substantially all of the product which had been contained in the bulk

receiving tank 22 has now been transferred to the bulk storage tank 206 in undiluted usable form,

with an insignificant amount of product discarded.

Transfer of Product from a Bulk Storage Tank to a Blend Tank

Once the bulk storage tank 206 has been loaded with product the system is ready to

transfer product from bulk storage tank 206 to a blend tank 222 (or, alternatively, any other

process tank). Initially, close the blend tank second divert valve 230 so that no rinse water 302

can escape from the blend tank 222. Then rinse the product lines and equipment in a bulk storage

tank product recovery module 216, a blend tank first divert valve 220, and the blend tank 222,

according to the "Product Recovery Module Initial Water Rinse Procedure" (FIG. 3, described

below in Section II.B.1), with the blend tank first divert valve 220 open to the blend tank 222 so

that the rinse water 302 (FIG. 3) will flow into the blend tank 222. Allow the rinse water to

accumulate in the blend tank 222. The second step is to evacuate the rinse water 302 from the product lines and equipment

in the bulk storage tank product recovery module 216, first divert valve 220, and blend tank 222,

using compressed air/gas, all according to the "Product Recovery Module - Rinse Water Air/Gas

Evacuation Procedure" (FIG. 3, described below in Section II.B.2). After substantially all of the

rinse water is pushed into the blend tank 222, open a blend tank second divert valve 230 to a

blend tank drain 226 and allow the accumulated rinse water to drain away.

The third step is to transfer the product from the bulk storage tank 206, through the bulk

storage tank product recovery module 216, and into the blend tank 222, all according to the

"Product Recovery Module Product Transfer Procedure" (FIG. 3, described below in Section II.B.3).

The fourth step is to recover the residual product from the bulk storage tank 206, bulk

storage tank product recovery module 216, and first divert valve 220, and expel the recovered

product into the blend tank 222, all according to the "Product Recovery Module Product

Recovery" procedure (FIG. 3, described below in Section II.B.4). At this point in time,

substantially all of the product which had been contained in the bulk storage tank 206 has been

transferred to the blend tank 222.

3. Transfer of Product from a Blend Tank To a Line Tank

Once the blend tank 222 has been loaded with product the system is ready to transfer

product from the blend tank 222 to a line tank 238, or, alternatively, any other process tank. The

blend tank 222 can also be used as a vessel in which finished product is initially created by

blending water with product concentrate or powdered product.

The first step is to rinse the product lines and equipment in the blend tank product

recovery module 232, a line tank first divert valve 236, and the line tank 238, according to the "Product Recovery Module - Initial Water Rinse Procedure" (FIG. 3, described below in Section

II.B.1), with the line tank first divert valve 236 open to the line tank 238 so that the rinse water

302 (FIG. 3) will flow into the line tank 238. Allow water 302 to accumulate into the line tank

238

The second step is to evacuate the rinse water from the product lines and equipment in

the blend tank product recovery module 232, as well as the valve 236 and the line tank 238, using

compressed air/gas, all according to the "Product Recovery Module - Rinse Water Air/Gas

rinse water is pushed into the line tank 238, open a line tank second divert valve 246 to a line tank

drain 242, and allow the accumulated rinse water to drain away.

The third step is to transfer product from the blend tank 222, through the blend tank

product recovery module 232, and into line tank 238, all according to the 'Troduct Recovery

Module - Product Transfer Procedure" (FIG. 3, described below in Section II.B.3).

The fourth step is to recovery the residual product from the blend tank 222, the blend tank

product recovery module 232, and first divert valve 236, and expel the recovered product into

the line tank 238, all according to the "Product Recovery Module Product Recovery Procedure"

(FIG. 3, described below in Section II.B.4). At this point in time, substantially all of the product

which had been contained in the blend tank 222 has been transferred to the line tank 238.

4. Transfer of Product from a Line Tank To a Balance Tank in a Container Line

Once line tank 238 has been loaded with product the system is ready to transfer product

from the line tank 238 to a balance tank in a container filling line. This process is described

separately in each of the four examples which follow the description of FIG. 3. B. DESCRDTTION OF FIG.3

The product recovery modules consist of product lines and equipment which are operated

according to sequential procedures in order to accomplish tank-to-tank product recovery. These

four procedures are, in sequential order: 1) Initial Water Rinse Procedure; 2) Rinse Water Air/Gas

Evacuation Procedure; 3) Product Transfer; and 4) Product Recovery Procedure.

1. Product Recovery Module -

Initial Water Rinse Procedure

In order to prepare the system for the transfer of product from one tank to another tank,

the first step is to send product recovery module water 302 through a product recovery module

"T" valve 303 into a product recovery module product line 304 so that water 302 thoroughly

rinses product line 304, a product recovery module first check valve 306, a product recovery

module pump 310, a product recovery module second check valve 314, a product recovery

module sight glass 316, and a product recovery module divert valve 318. The divert valve 318

is opened so that water 302 continues through the following product intake lines: the bulk storage

tank product intake line 202, the blend tank product intake line 218, and line tank product intake

line 234; the following divert valves: the bulk storage tank first divert valve 204, the blend tank

first divert valve 220, and the line tank first divert valve 236; and into the following tanks: the

bulk storage tank 206, the blend tank 222, and the line tank 238. Run water 302 through all of

this equipment until it is thoroughly rinsed, preferably at a flow rate approximately equivalent to

80 g.p.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, for approximately

60 seconds, or as required. Discontinue the flow of the water 302 and allow the water to drain

from the lines and equipment and accumulate in the bulk storage tank 206, the blend tank 222,

or theline tank 238. 2. Product Recovery Module -

Rinse Water Air/gas Evacuation Procedure

Prior to the present invention, the rinse water left in the system was pushed out of the system by using the very product which . Because a large quantity of product was diluted by this contact with the rinse water, a large quantity of product was thus rendered unusable by this approach. This unusable product was typically diverted down into a drain until sensors or human operators determine that the product flowing through the system was no longer diluted by rinse water. Then the full strength product was diverted back into the container filling system. In this invention, compressed FDA quality air or gas is used to evacuate the rinse water, creating a sterile buffer between the rinse water and the product. This approach entirely avoids the prior problem of product dilution by the initial rinse water in the system.

Because of the typical size of pumps used for pump 310, twenty or more gallons of water

will often remain after water 302 is allowed to drain from pump 310. In order to thoroughly clear

pump 310 of water, send compressed air/gas 305 through first check valve 306 for approximately

at least 10 seconds at a flow rate approximately equivalent to 80 cfm. within a schedule 40 steel pipe having a nominal diameter of 2 inches, to push any remaining rinse water in product line 304

through and past pump 310 and second check valve 314.

Through second check valve 314, send compressed air/gas 312 for approximately at least two minutes (the actual time necessary is dictated by the size and length of product lines to be cleared) at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, through that portion of product line 304, to expel the remaining

rinse water through sight glass 316, divert valve 318, product intake lines 202, 218, and 234, first

divert valves 204, 220, and 236, and into bulk storage tank 206, blend tank 222, and line tank

238. After compressed air/gas 312 flow through these lines and equipment at an appropriate before rate and for an appropriate period of time based upon the size and length of product line

304, and product intake lines 202, 218, and 234, compressed air/gas 312 will have expelled all

remaining water 302 into a bulk storage tank 206, blend tank 222, and line tank 238.

At this point in time product line 304, and all the equipment it interconnects, and product

intake lines 202, 218, and 234, have been rinsed with water 312, and water 312 has been

thoroughly evacuated by use of compressed air/gas 305 and compressed air/gas 312..

3. Product Recovery Module - Product Transfer Procedure In order to begin transferring product through the product recovery module, product is

introduced into product line 304 and into pump 310. Once pump 310 is primed with product,

activate pump 310 to begin pumping product through product line 304 into product intake lines

202, 218, and 234, and into bulk storage tank 206, blend tank 222, and line tank 238. Pump 310

will continue to operate until there is insufficient product left to prime pump 310. At this stage

of the process, that portion of product line 304 downstream from pump 310, and product intake

lines 202, 218, and 234, and all the equipment those lines interconnect, are all fully charged with

undiluted, usable product. Pump 310, however, is not able to continue pumping since it is no

longer primed with product, and so the system must be cleared by another means..

4. Product Recovery Module - Product Recovery Procedure

Prior to the present invention, rinse water was used to push the remaining product through

pump 310, product line 304 and product intake lines 202, 218, and 234, thus diluting a substantial

quantity of the remaining product and rendering it unusable. This diluted product would then be

dumped down a drain - a wasteful and costly approach. In the present invention, the product remaining in pump 310, product line 304, and

product intake lines 202, 218, and 234, is recovered using the air/gas evacuation approach. After

pump 310 can no longer pump any further product down product line 304 and pump 310 has been

deactivated, send compressed air/gas 305 through first check valve 306 for approximately at least

10 seconds at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe

having a nominal diameter of 2 inches, through product line 304, and pump 310 to push any

remaining product through product line 304, and past pump 310, and past second check valve 314

Immediately send compressed air/gas 312 through second check valve 314 for

approximately at least 2 minutes at a flow rate approximately equivalent to 80 c.f.m. within a

schedule 40 steel pipe having a nominal diameter of 2 inches, (the actual time and flow rate

necessary is dictated by the size and length of product lines to be cleared) through product line

304, second check valve 314, sight glass 316, divert valve 318, product intake lines 202, 218, and

234, first divert valves 204, 220, and 236, into bulk storage tank 206, blend tank 222, and line

tank 238. Before turning off the flow of compressed air/gas 312, utilize sight glass 316, or a

suitable automatic sensory device, and verify that there is no product remaining in product line

304. Then wait for compressed air/gas 312 to expel the remaining product in intake lines 202,

218, and 234. With compressed air/gas 312 still flowing, turn off first divert valves 204, 220, and

236, and open divert valve 318 to product recovery module drain 320. At this point a very small

amount of product residue is expelled into drain 320. Open first divert valves 204, 220, and 236,

to bulk storage tank drain 210, blend tank drain 226, and line tank drain 242, and re-open divert

valve 318 to product intake lines 202, 218, and 234. The remaining product residue will be

expelled into drains 210, 226, and 242. Shut off the flow of compressed air/gas 312. At the end of each product evacuation procedure, an optional rinse procedure may be

performed. This is particularly useful if the filling line operator desires to switch from one

product to another while the container line remains in substantially constant operation. If the

optional rinse procedure is used at the end of each Product Recovery Procedure, then there may

be no need to use the initial water rinse procedure prior to switching to and transferring a new

product. This procedure, however, is at the filling line operator's discretion depending upon the

types of products, regulatory requirements, or the customary practice of the particular filling

plant.

The optional rinse procedure begins by sending water 302 through "T" valve 303, into

product line 304 so that water 302 thoroughly rinses product line 304, first check valve 306,

pump 310, second check valve 314, sight glass 316, and divert valve 318. Divert valve 318 is

opened so that water 302 continues through product intake lines 202, 218, and 234, to first divert

valves 204, 220, and 236. At this point in time, first divert valves 204, 220, and 236 remain open

so that water 302 empties into drains 210, 226, and 242. Run water 302 through all of this

equipment at a flow rate approximately equivalent to 80 g.p.m. within a schedule 40 steel pipe

having a nominal diameter of 2 inches, for approximately 90 seconds. Discontinue the flow of

the water 302 and allow the water to drain into drains 210, 226, and 242. Product line 304 and

product intake lines 202, 218, 234 have now been rinsed clean.

C. PREFERRED COMPONENTS.

In one preferred embodiment of the product recovery modules, the following items have

been used successfully, although other items which function in an equivalent manner can also be

used:

Water 302 Approved government standards drinking water or approved process water. Air/gas 305, 312 For food and drug related applications of the present invention, Food and Drug Administration (FDA) grade sanitary air is preferably obtained by three stage Filenco Dryer/Filters to filter and dry high pressure compressed air on a point-of-use basis immediately prior to the introduction of the compressed air/gas to the check valves 306 and 314. Alternately, regular atmosphere air, or any inert or non-reactive gas, if filtered and dried properly, can be used for compressed air/gas 305 and 312 in non-food and non-drug applications of the present invention.

Check Valves 306, 312 Tri-Clover 316 stainless steel ball check valve with Tri- Clover 316 stainless steel air/gas blow attachment. Pump 310 Tri Clover 316 stainless steel food grade sanitary pump. Both centrifical and positive displacement type pumps have been successfully utilized.

Product Line 304 316 stainless steel lines, approximately two inches in diameter.

Sight Glass 316 Jensen 316 stainless steel sight glass.

Divert Valves 308, 318 Tri Clover 316 stainless steel pneumatic divert valve or Tri Clover 316 stainless steel 3 way manual valve.

Product Intake Lines 202, 218, and 234 316 stainless steel lines, approximately two inches in diameter.

HI. CONTAINER FILLING LINE PRODUCT RECOVERY

The methods and apparatus for product recovery represented by this invention are not

restricted to the recovery of product during a truck-to-tank transfer or a tank-to-tank transfer of product. This new invention can also be applied to the recovery of product from the product lines

and equipment used in filling lines as well. This invention has been successfully tested on filling

lines in three different configurations, which will be discussed below as Example 1 (Section A),

Example 2 (Section B), and Example 3 (Section C). An additional example, Example 4 (Section

D), embodies an improvement to the filling line recovery system described in Example 1.

A. EXAMPLE 1 (FIGS.4, 2A AND 2) 1. Filler Line Rinse Procedure

Using clean fresh safe balance tank spray ball water 406, pre-rinse a balance tank 403 and

allow the rinse water to drain through a balance tank second valve 408, a balance tank first check

valve 410, and a balance tank divert valve 411 into a balance tank drain 469. Using clean fresh

filler feed tank spray ball water 431, pre-rinse a filler feed tank 430 and allow the rinse water to

drain through a filler feed tank first check valve 434 and a filler feed tank divert valve 435 into

a filler feed tank drain 436. Using clean, fresh, safe filler return tank spray ball water 449, pre-

rinse a filler return tank 448, and allow the rinse water to drain through a filler return tank first

check valve 453 and a filler return tank first divert valve 454 into a filler return tank drain 455.

Verify that the line tank valve second divert valve 246 (FIG. 2) is closed. Send water 302

(FIG. 3) through the product line 304 (FIG. 3) and all the equipment identified in the line tank

product recovery module 248 (See FIGS. 2 and 3) and into the line tank product line 250 (FIG.

2), through a balance tank first valve 402, and into the balance tank 403. Fill the balance tank

approximately 50% to 75% full, verifying the fill level by use of a balance tank sight glass 407

or other suitable automatic sensory device. Open the balance tank second valve 408 and allow

water 302 to flood through a balance tank product line 401 into the balance tank first check valve

410, the balance tank divert valve 411, and into a balance tank pump 412, thus priming the

balance tank pump. Activate the balance tank pump and pump water 302 forward into the

following equipment interconnected by the balance tank product line 401 : a balance tank second

check valve 414; a balance tank "T" valve 415 (with optional source of water 472 attached); a

pasteurizer/cooler 416; a pasteurizer/cooler R.T.D. sensor 419; a heat retention loop 420; zone

heater/coolers 421; a zone heater/cooler R.T.D. sensor 424; a zone heater/cooler sight glass 425;

a heat exchanger 426; a heat exchanger first divert valve 427 and into a filler feed tank 430. Continue pumping water 302 through the balance tank product line 401 until water 302

completely fills the filler feed tank 430. Water 302 then overflows through a filler feed tank

overflow line 441 into a filler return tank 448. Open the filler feed tank first check valve 434 and

allow water 302 to also flow through a filler feed tank product line 440 into a filler feed return

tank divert valve 435 and into a filler feed tank pump 437, thus priming the filler feed tank pump.

Activate the filler feed tank pump and pump water 302 through the filler feed tank product line

440 and into a filler feed tank second check valve 439, the heat exchanger 426, a filler R.T.D.

sensor 442, a filler divert valve 443, and into a filler 445. Rinse the filler 445 for approximately

ten seconds, then open the filler divert valve 443 so that the water 302 is diverted into a filler

bypass product line 446, and then into a filler overflow product line 447, and then into the filler

return tank 448.

Open a filler return tank first check valve 453 so that water 302 floods out through a filler

return tank product line 451 into a filler return tank first divert valve 454, and into a filler return

tank pump 456, thus priming the filler return tank pump. Turn a filler return tank 3 -way switch

471 to the "on" position to activate the filler return tank pump and pump water 302 through the

product line 451 into a filler return tank second check valve 458, a filler return tank second divert

valve 459 open to a balance tank return product line 473, through a filler return tank third check

valve 463, a balance tank heater/cooler 464, a balance tank heater/cooler sight glass 467, a

balance tank heater/cooler divert valve 468, and into the balance tank 403. For approximately

15 seconds, open the filler return tank second divert valve 459 so that water 302 is diverted

through a filler return tank second divert product line 460, a filler return tank second divert valve

sight glass 461, and back into the filler feed tank 430. Reopen the return tank second divert valve

459 to send water 302 back through the balance tank return product line 473. Turn off all system pumps, namely the balance tank pump 412, the filler feed tank pump

437, and the filler return tank pump 456. Open all divert-to-drain valves to their respective

drains, namely the balance tank divert valve 411 to the balance tank drain 469, the heat exchanger

first divert valve 427 to heat exchanger drain 429, the filler feed tank divert valve 435 to the filler

feed tank drain 436, the filler return tank first divert valve 454 to the filler return tank drain 455,

and the heater/cooler divert valve 468 to the balance tank drain 469.

2. Filler Line Rinse Water Air/Gas Evacuation Procedure

In consecutive sequence, send compressed air/gas through each of the following check

valves, preferably for approximately 30 seconds at a flow rate approximately equivalent to 80

c.f.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, or as required to

thoroughly evacuate rinse water from the desired product lines and equipment:

a. Compressed air/gas 305 through check valve 306 (FIG. 3) in the line tank

product recovery module 248 (FIG. 2).

b. Compressed air/gas 312 through check valve 314 (FIG. 3) in the line tank

product recovery module 248 (FIG. 2).

c. Compressed air/gas 409 through the balance tank first check valve 410.

d. Compressed air/gas 413 through the balance tank second check valve

414.

e. Compressed air/gas 433 through the filler feed tank first check valve 434.

f Compressed air/gas 438 through the filler feed tank second check valve

439.

g. Compressed air/gas 452 through the filler return tank first check valve

453. h. Compressed air/gas 457 through the filler return tank second check valve

458 for approximately 45 seconds, making sure to open the filler return

tank divert valve 459 for approximately 15 seconds to clear the product

line 460 of rinse water.

i. Compressed air/gas 462 through the filler return tank third check valve

463.

The compressed air/gas flowing through all of the product lines, tanks, and equipment

in the filler line in this fashion evacuates substantially all of the rinse water in the filler line. Now,

when product flows through the filler line, substantially all of the product remains undiluted by

residual rinse water and thus remains usable. No product is wasted in order to expel used rinse water from the filler line. At this stage of the process, the filler line is rinsed, the rinse water has

been expelled, and the filler line is now ready for the introduction of product.

3. Filler Line Product Transfer

Reopen all divert-to-drain valves to their respective product lines, namely the balance tank

divert valve 411 to the product line 401, the heat exchanger first divert valve 427 to the product

line 401, the filler feed tank divert valve 435 to the product line 440, the filler return tank first

divert valve 454 to the product line 451, and the heater/cooler divert valve 468 to the balance

tank return product line 473. Close the balance tank second valve 408. Open the line tank second

valve 246 (FIG. 2) so that product flows into the line tank product line 250, and through product

line 304 of the line tank product recovery module 248 (FIGS. 2 and 3) into the "T" valve 303

(FIG. 3), the first check valve 306 (FIG. 3), and into the pump 310, thus priming the pump 310

(FIG. 3). Turn the balance tank 3-way switch 405 to the "auto" position, so that the switch

responds to signal input 404a from the balance tank high/low probe 404. The high/low probe will

signal the 3-way switch 405 to activate the line tank pump 310 if the product level in the balance

tank 403 drops below a predetermined setting, and will signal the 3-way switch to turn the line

tank pump off if the product level rises above a predetermined setting in the balance tank. Since

the balance tank 403 is presently empty of both product and rinse water, turning the 3-way switch

405 to the "auto" position will activate the line tank pump 310 and fill the balance tank to a

predetermined level.

Open the balance tank second valve 408 and allow product to flood through the balance

tank product line 401 into the balance tank first check valve 410, the balance tank divert valve

411, and into the balance tank pump 412, thus priming the pump 412. Activate the pump 412 and

pump product forward into the following equipment interconnected by the balance tank product

line 401: the balance tank second check valve 414; the balance tank "T" valve 415 (with optional

source of water 472 attached); the pasteurizer/cooler 416; the pasteurizer/cooler R.T.D. sensor

419; the heat retention loop 420; the zone heater/coolers 421; the zone heater/cooler R.T.D.

sensor 424; the zone heater/cooler sight glass 425; the heat exchanger 426; the heat exchanger

first divert valve 427 and into the filler feed tank 430. Open the filler feed tank first check valve

434 and allow product to flow through the filler feed tank product line 440 into the filler feed

return tank divert valve 435 and into the filler feed tank pump 437, thus priming the pump 437.

Turn the heat exchanger 3-way switch 444 to the "auto" position, so that the switch

responds to a signal input 442a from the filler R.T.D. sensor 442. The R.T.D. sensor will signal

a filler 3-way switch 444 to activate the filler divert valve 443 to divert product to the filler bypass

product line 446 if the product temperature is outside of a predetermined range of high and low temperature. Too low a temperature could render some products unsafe due to a lack of effective

pasteurization. Too high a temperature could result in excessively hot product damaging plastic

containers which may be used in some situations. For other products a cold temperature is

desired. For example, carbonated beverages must be bottled at cold temperatures to maintain

proper carbonation. The R.T.D. sensor will signal the filler 3-way switch 444 to activate the filler

divert valve 443 to divert product to the filler 445 if the product temperature is within a

predetermined range of high and low temperature, i.e. when the product is "at temperature."

Since it takes several minutes for the product temperature to be adjusted to the proper level by

the pasteurizer/cooler 416 and/or the zone heater/cooler 421, turning the filler 3-way switch 444

to the "auto" position at this time will activate the filler divert valve 443 to divert product to the

filler bypass product line 446.

Activate the filler feed tank pump 437 and pump the product through the filler feed tank

product line 440 and into the filler feed tank second check valve 439, the heat exchanger 426, the

filler R.T.D. sensor 442, and to the filler divert valve 443. Product will flow into the filler bypass

product line 446 until the R.T.D. sensor 442 senses that product temperature is within the

predetermined range.

Until the product is "at temperature," it will continue to flow through the filler bypass

product line 446, and then into the filler overflow product line 447, and then into the filler return

tank 448. Open the filler return tank first check valve 453 so that product flows out through the

filler return tank product line 451 into the filler return tank first divert valve 454, and into the filler

return tank pump 456, thus priming the pump 456.

Turn the filler return tank 3-way switch 471 to the "auto" position, so that the switch

responds to a signal input 470a from the balance tank high/low probe 470. The filler return high/low probe will signal the filler return tank 3-way switch 471 to send a signal input 471 A to

activate the filler return tank pump 456 when the product level in the filler return tank 448 rises

to a predetermined level, and will signal the 3-way switch to turn the line tank pump off if the

product level falls below a predetermined setting in the filler return tank. Since the filler return

tank is presently filling with product, turning the 3-way switch 471 to the "auto" position will

activate the filler return tank pump when the product in the filler return tank reaches the

predetermined level in the tank. Once the filler return tank pump activates, the product is pumped

through the product line 451 into the filler return tank second check valve 458, the filler return

tank second divert valve 459 open to the balance tank return product line 473, the filler retum

tank third check valve 463, the balance tank heater/cooler 464, the balance tank heater/cooler

sight glass 467, the balance tank heater/cooler divert valve 468 open to the balance tank return

product line 473, and into the balance tank 403.

Balance tank product return line heater/cooler 464 is used to adjust the temperature of

product being returned back into the balanced/filler feed tank. The heater/cooler adjusts the temperature of the product flowing through it by means of a balance tank product return line

heater/cooler hot/cold service 465, which circulates service water through the heater/cooler by

means of a balance tank product return line heater/cooler hot/cold service supply line 466. For

those products which are placed into containers while warm or hot, the return line heater/cooler

464 is used is lower the temperature of the product returning to the balance tank 403 to

approximately match the temperature of the product flowing into the balance tank from the line

tank. For those products which are placed into containers while cool or cold, the return line

heater/cooler is used is raise the temperature of the product returning to the balance tank to

approximately match the temperature of the product flowing into the balance tank from the line tank. Product is now flowing completely through the filler line depicted in FIG. 4, except for

the filler 445. Set the temperature at the controller (not shown) for hot/cold service 417. The

pasteurizer/cooler 426 utilizes service water from the pasteurizer/cooler hot/cold service. This

service water circulates through the pasteurizer/cooler by means of a pasteurizer/cooler service

line 418, and is used to adjust the temperature of the product to the desired temperature. The

pasteurizer/cooler R.T.D. sensor 419 senses the temperature of the product leaving the

pasteurizer/cooler and sends a signal 419a back to the pasteurizer/cooler hot/cold service to

automatically regulate the product temperature. The heat retention loop 420 is optionally used

to help maintain the temperature of the product for an extended period of time after the product

leaves the pasteurizer/cooler 416.

The zone heater/cooler 421 is used to adjust the temperature of the product after it has

left the pasteurizer/cooler 416. The zone heater/cooler utilizes service water from the zone

heater/cooler hot/cold service 422. This service water circulates through the zone heater/cooler

by means of a zone heater/cooler service supply lines 423, and is used to further adjust the

temperature of the product to a desired temperature. The zone heater/cooler R.T.D. sensor 424

senses the temperature of the product leaving the pasteurizer/cooler and sends a signal 424a back

to the zone heater/cooler hot/cold service 422 to automatically regulate the product temperature.

The heat exchanger 426 is utilized during this entire process to help preserve the desired

product temperature. When the product reaches the proper temperature range (as set at the filler

R.T.D. sensor 442), the filler divert valve 443 is automatically activated by the filler 3-way switch

444 to divert product into the filler 445.

Containers are now sent to the filler 445 and filled with product. This process continues

until the end of the run, or until a product change. 4. Filler Line Product Recovery Procedure

Once the line tank goes empty, turn the balance tank 3-way switch 405 to the "off"

position, thus turning off the line tank pump 310 in the line tank product recovery module 248

(See FIGS. 2 and 3). Send approximately 15 seconds of compressed air/gas 305 at a flow rate

of 2 inches, through the check valve 306 (in line tank product recovery module 248) to evacuate

substantially all the product from that portion of the product line 304 preceding the pump 310 and

past the check valve 314. Send approximately 20 seconds of compressed air/gas 312 at a flow

rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe having a nominal

diameter of 2 inches, through the check valve 314 (in line tank product recovery module 248) to

evacuate the remainder of product from the product line 304, the line tank product line 250, and

into the balance tank 403.

When the balance tank 403 is nearly empty of product (approximately 50 gallons

remaining or at the filler operator's discretion), open the filler return tank second divert valve 459

to divert product into a filler return tank second divert valve product line 460, thus returning the

product back into the filler feed tank 430. Send approximately 30 seconds of compressed air/gas

462 at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe having

a nominal diameter of 2 inches, through the filler return tank third check valve 463 to evacuate

the remainder of product from the balance tank return product line 473, the balance tank

heater/cooler 464, the balance tank heater/cooler sight glass 467, the balance tank heater/cooler

divert valve 468, and into the balance tank 403.

When the balance tank 403 goes completely empty, turn the balance tank pump 412 off.

Close the balance tank valve 408. Immediately send approximately 30 seconds of compressed air/gas 409 at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe

having a nominal diameter of 2 inches, through the balance tank first check valve 410 to evacuate

the remainder of product from the balance tank product line 401, the balance tank divert valve

411, the balance tank pump 412, the balance tank second check valve 414, the balance tank "T"

valve 415 (with optional source of water 472 attached); the pasteurizer/cooler 416; the

pasteurizer/cooler R.T.D. sensor 419; the heat retention loop 420; the zone heater/coolers 421;

the zone heater/cooler R.T.D. sensor 424; the zone heater/cooler sight glass 425; the heat

exchanger 426; the heat exchanger first divert valve 427 and into the filler feed tank 430. The

filler line operator should use the sight glass 425, or any other suitable sensor device, to verify

that substantially all the product has been evacuated into the filler feed tank 430. Once this

occurs, turn off the compressed air/gas 413 and close the balance tank second check valve 414.

Immediately send water 472 into the balance tank "T" valve 415 and into the balance tank product

line 401. Open the heat exchanger first divert valve 427 to the heat exchanger drain 429 via the

heat exchanger sight glass 428.

Water 472 is now being heated or cooled to the desired temperature by the

pasteurizer/cooler 416 and/or the zone heater/cooler 421. The temperature adjusted water 472

now becomes service water in the heat exchanger 426 to maintain or adjust the temperature of

the remainder of product being circulated through the heat exchanger 426 and between the filler

feed tank 430, the filler 445, and the filler return tank 448.

As the quantity of product becomes depleted, slow down the filler 445 and continue filling

containers with product, which is maintained "at temperature" by circulating both product and

temperature adjusted water 472 through the heat exchanger 426. Continue slowing down the filler 445 and filling containers until the filler return tank 448

is empty, as verified by visual inspection of the filler return tank sight glass 450, or as verified by

use of any other suitable sensory device. Turn the filler return tank 3-way switch 471 to the "off"

position, thus deactivating the filler return pump 456. Send approximately 20 seconds of

compressed compressed air/gas 452 at a flow rate approximately equivalent to 80 c.f.m. within

a schedule 40 steel pipe having a nominal diameter of 2 inches, through the balance tank first

check valve 453 to evacuate the remainder of product from the filler return tank product line 451,

the filler return tank first divert valve 454, the filler return tank pump 456, the filler return tank

second check valve 458, the filler return tank second divert valve 459, into the filler return tank

second divert valve product line 460, through the filler return tank second divert valve sight glass

461, and into the filler feed tank 430.

Once the filler feed tank 430 is empty of product, turn off the filler feed tank pump 437.

Send approximately 30 seconds of 15 to 20 p.s.i. compressed air/gas 433 through the filler feed

tank first check valve 434 through the filler feed tank product line 440, the filler feed tank divert

valve 435, the filler feed tank pump 437, the filler feed tank second check valve 439, the heat

exchanger 426, the R.T.D. sensor 442, the filler divert valve 443 and into the filler 445. The use

of temperature adjusted water 472 circulating through the heat exchanger 426 has maintained all

the remaining evacuated product "at temperature" so that substantially all of the remaining

product can be placed into containers at the filler 445 at approved temperature.

When the last container is filled, substantially all of the product originally introduced into

the filler line has been placed into containers. Turn off the water 472. Turn the hot/cold service

417 off. Repeat the entire rinse procedure detailed in Section III. A.1 above, titled "Filler Line

Rinse Procedure," and the entire air/gas evacuation procedure described above in Section III. A.2, titled, 'Tiller Line Rinse Water Air/Gas Evacuation Procedure." The filler line depicted in FIG.

4 is now ready for a product change, or ready to be shut down.

B. EXAMPLE 2 (FIGS. 5, 2B AND 2)

1. Filler Line Rinse Procedure

Using balance/filler feed tank spray ball water 506, pre-rinse a balance/filler feed tank 503

and allow the rinse water to drain through a balance/filler feed tank second valve 508, a

balance/filler feed tank first check valve 510, and a balance/filler feed tank divert valve 511 into

a balance/filler feed tank drain 569. Using filler return tank spray ball water 549, pre-rinse a filler

return tank 548, and allow the rinse water to drain through a filler return tank first check valve

553 and a filler return tank first divert valve 554 into a filler return tank drain 555.

Verify that the line tank second valve 246 (FIG. 2) is closed. Send water 302 (FIG. 3)

through the product line 304 (FIG. 3), and all the equipment identified in line tank product

recovery module 248 (See FIGS. 2 and 3), and into the line tank product line 250 (See FIGS. 2

and 3), through the balance/filler feed tank first valve 502, and into the balance/filler feed tank

503. Fill the balance/filler feed tank 503 approximately 50% to 75% full, verifying the fill level

by use of balance/filler feed tank sight glass 507, or alternately a suitable automatic sensory

device. Open the balance/filler feed tank second valve 508 and allow the water 302 to flood

through the balance/filler feed tank product line 501 into a balance/filler feed tank first check valve

510, a balance/filler feed tank divert valve 511, and into a balance/filler feed tank pump 512. The

rinsing water 302 thus primes the pump 512. Activate the pump 512 and pump the water forward

into the following equipment interconnected by balance/filler feed tank product line 501: a

balance/filler feed tank second check valve 514, a balance/filler feed tank "T" valve 515 , a

pasteurizer/cooler 516, a pasteurizer/cooler R.T.D. sensor 519, a heat retention loop 520, a zone heater/cooler sight glass 525, a zone heater/coolers 521, a zone heater/cooler R.T.D. sensor 524,

a heat exchanger first divert valve 527, a heat exchanger first check valve 529, a heat exchanger

526, a filler R.T.D. sensor 542, a filler divert valve 543 and into a filler 545.

Open the heat exchanger first divert valve 527, preferably for approximately 15 seconds

or as required to perform an adequate rinse, to divert water 302 through a heat exchanger product

line 541 , a heat exchanger sight glass 528, the heat exchanger 526, a heat exchanger second divert

valve 535, and into the filler return tank 548. After the heat exchanger product line 541, and the

equipment it interconnects, have been thoroughly rinsed, open the heat exchanger first divert

valve 527 to divert water 302 back into balance/filler feed tank product line 501.

Preferably for approximately 15 seconds, or as required to accomplish a thorough rinse,

open a filler divert valve 543 so that the water 302 is diverted through a filler bypass product line

546 into a filler overflow product line 547, and into the filler return tank 548. Then, re-open filler

divert valve to the filler 545.

Continue pumping the water 302 through the balance/filler feed tank product line 501,

into the filler 545. As the water 302 floods through the filler 545, water 302 will continue to flow

through the filler overflow product line 547 and into the filler return tank 548.

Open a filler return tank first check valve 553 so that the water 302 floods out through

a filler return tank product line 551 into a filler return tank first divert valve 554, and into a filler

return tank pump 556, thus priming the pump. Turn a filler return tank 3-way switch 571 from

the "auto" position to the "on" position to activate the pump 556 and pump the water 302

through the product line 551 into a filler return tank second check valve 558, a filler return tank

second divert valve 559, a balance/filler feed tank product retum line 573, through a filler return

tank third check valve 563, a balance/filler feed tank product return line heater/cooler 564, a heater/cooler sight glass 567, a balance/filler feed tank product return line heater/cooler divert

valve 568, and to the balance/filler feed tank 503.

open the filler return tank second divert valve 559 so that the water 302 is diverted through a filler

return tank second divert product line 560 into a filler return tank second divert valve sight glass

561, a heat exchanger second check valve 574 and into the balance/filler feed tank product line

501

Turn off all system pumps, namely the balance/filler feed tank pump 512 and the filler

return tank pump 556. Open all divert-to-drain valves to their respective drains, namely the

balance/filler feed tank divert valve 511 to the drain 569 , the heat exchanger second divert valve

535 to a heat exchanger drain 536, the filler return tank first divert valve 554 to the drain 555, and

the balance/filler feed tank product return line heater/cooler divert valve 568 to the drain 569.

Allow the entire system to drain rinse water from the filler lines and equipment into the open

drains.

2. Filler Line Rinse Water Air/Gas Evacuation Procedure

In consecutive sequence, send compressed air/gas through the following check valves,

preferably for approximately 30 seconds of at a flow rate approximately equivalent to 80 c.f.m.

within a schedule 40 steel pipe having a nominal diameter of 2 inches, or as required to thoroughly

evacuate all rinse water from the desired product lines and equipment:

a. Compressed air/gas 305 through product recovery module first check

valve 306 (FIG. 3) in line tank produce recovery module 248 (FIG. 2).

b. Compressed air/gas 312 through product recovery module second check

valve 314 (FIG. 3) in line tank produce recovery module 248 (FIG. 2). c. Compressed air/gas 509 through balance/filler feed tank first check valve

510.

d. Compressed air/gas 513 through balance/filler feed tank second check

valve 514.

e. Compressed air/gas 552 through filler return tank first check valve 553.

f Compressed air/gas 557 through filler return tank second check valve 558,

preferably for approximately 45 seconds total, including approximately 15

seconds with the filler return tank second divert valve 559 open to the

product line 560 in order to clear the product line 560 of rinse water.

g. Compressed air/gas 562 through filler return tank third check valve 563.

in the filler line, as illustrated in FIGS. 2, 3, and 5, evacuates substantially all of the rinse water

in the filler line. Thus, in the present invention, when product flows through the filler line,

substantially all of the product remains undiluted by residual rinse water and therefore remains

usable. No product is wasted in order to expel used rinse water from the filler line. At this stage

of the process, the filler line is now rinsed, the rinse water has been expelled, and the filler line is

ready for the introduction of the product from the line tank.

3. Filler Line Product Transfer

Reopen all divert-to-drain valves to their respective product lines, namely the balance/filler

feed tank divert valve 511 to the product line 501, the heat exchanger second divert valve 535 to

the product line 540, the filler return tank first divert valve 554 to the product line 551, and the

balance/filler feed tank product return line heater/cooler divert valve 568 to the balance/filler feed

tank return product line 573. Close the balance/filler feed tank second valve 508. Open the line tank second valve 246 (FIG. 2) so that the product flows into the line tank product line 250, and

through the product line 304 of the line tank product recovery module 248 (FIGS. 2 and 3) into

the "T" valve 303 (FIG. 3), the first check valve 306 (FIG. 3), and into the pump 310. The

product thus primes the pump 310 (FIG. 3).

Turn a balance/filler feed tank 3-way switch 505 to the "auto" position, so that the switch

responds to a signal input 504A from a balance/filler feed tank high/low probe 504. The high/low

probe will signal the 3-way switch 505 to send a signal input 505 A to line tank pump 310 (FIGS.

2 and 3) if the product level in the balance/filler feed tank 503 drops below a predetermined

setting, and will signal the 3-way switch to turn the line tank pump off if the product level rises

above a predetermined setting in the balance/filler feed tank. Since balance/filler feed tank 503

is presently empty of both product and rinse water, turning the 3-way switch 505 to the "auto"

position will activate the line tank pump 310 and fill the balance/filler feed tank to a

predetermined level.

Open the balance/filler feed tank second valve 508 and allow product to flood through the

balance/filler feed tank product line 501 into the balance/filler feed tank first check valve 510, the

balance/filler feed tank divert valve 511, and into the balance/filler feed tank pump 512, thus

priming the pump 512. Activate the pump 512 and pump product forward into the following

equipment interconnected by balance/filler feed tank product line 501: the balance/filler feed tank

second check valve 514, balance/filler feed tank "T" valve 515 , pasteurizer/cooler 516,

pasteurizer/cooler R.T.D. sensor 519; heat retention loop 520, zone heater/cooler sight glass 525,

zone heater/coolers 521, zone heater/cooler R.T.D. sensor 524, heat exchanger first divert valve

527, heat exchanger first check valve 529, heat exchanger 526, filler R.T.D. sensor 542, filler divert valve 543 (opened to filler bypass product line 546), filler bypass product line 546, return

tank product intake line 547 and into the filler return tank 548.

Turn a heat exchanger 3-way switch 544 from the "off" position to the "auto" position,

so that the switch responds to a signal input 542a from a filler R.T.D. sensor 542. The R.T.D.

sensor will signal the 3-way switch 544 to send a signal input 544 A to activate the filler divert

valve 543 to divert product to the filler bypass product line 546 if the product temperature is

outside of a predetermined range of high and low temperature. Too low a temperature could

render some products unsafe due to a lack of effective pasteurization. Too high a temperature

could result in excessively hot product damaging plastic containers which may be used in some

situations. For other products a cold temperature is desired. For example, carbonated beverages

must be bottled at cold temperatures to maintain proper carbonation. The R.T.D. sensor will

signal the 3-way switch 544 to activate the filler divert valve 543 to divert product to the filler

545 if the product temperature is within a predetermined range of high and low temperature, i.e.

when the product is "at temperature." Since it takes several minutes for the product temperature

to be adjusted to the proper level by the pasteurizer/cooler 516 and/or the zone heater/cooler 521,

turning the filler 3-way switch 544 to the "auto" position at this time will activate filler divert

valve 543 to divert product to heat exchanger second divert product line 546.

product line 546, and then into the filler overflow product line 547, and then into the filler return

tank 548. Open the filler return tank first check valve 553 so that product flows out through the

filler return tank product line 551 into the filler return tank first divert valve 554, and into the filler

return tank pump 556, thus priming the pump. Turn a return tank 3-way switch 571 to the "auto" position, so that the switch responds

to a signal input 570a from a filler return tank high/low probe 570. The filler return high/low

probe will signal the 3-way switch 571 to activate the filler return tank pump 556 when the

product level in the filler return tank rises to a predetermined level, and will signal the 3-way

switch to turn the line tank pump off if the product level falls below a predetermined setting in the

filler return tank. Since filler return tank is presently filling with product, turning the 3-way switch

505 to the "auto" position will activate the pump 556 when the product in the filler return tank

reaches the predetermined level in the tank.

Once the pump 556 activates, the product is pumped through the filler return tank

product line 551 into the filler return tank second check valve 558, the filler return tank second

divert valve 559 (which is open to balance/filler feed tank return product line 573), the

balance/filler feed tank return product line 573, the filler return tank third check valve 563, the

balance/filler feed tank product return line heater/cooler 564, the balance/filler feed tank product

return line heater/cooler sight glass 567, the balance/filler feed tank product return line divert

valve 568, and into the balance/filler feed tank 503.

Balance/filler feed tank product return line heater/cooler 564 is used to adjust the

temperature of product being returned back into the balance/filler feed tank 503. The

heater/cooler adjusts the temperature of the product flowing through it by means of a

balance/filler feed product return line heater/cooler hot/cold service 565, which circulates service

water through the heater/cooler by means of a balance/filler feed product return line heater/cooler

hot/cold service supply line 566. For those products which are placed into containers while warm

or hot, the return line heater/cooler 564 is used is lower the temperature of the product returning

to the balance/filler feed tank 503 to approximately match the temperature of the product flowing into the balance/filler feed tank from the line tank # (FIG. 2). For those products which are

placed into containers while cool or cold, the return line heater/cooler is used is raise the

temperature of the product returning to the balance/filler feed tank to approximately match the

temperature of the product flowing into the balance/filler feed tank from the line tank.

Product is now flowing completely through the filler line depicted in FIG. 5, except for

the filler 545. Set the temperature at the controller (not shown) for a pasteurizer/cooler hot/cold

service517. Pasteurizer/cooler utilizes service water from the pasteurizer/cooler hot/cold service

517. This service water circulates through the pasteurizer/cooler by means of a pasteurizer/cooler

service supply line 518, and is used to adjust the temperature of the product to the desired

temperature. The pasteurizer/cooler R.T.D. sensor 519 senses the temperature of the product

leaving the pasteurizer/cooler and sends a signal 519a back to the hot/cold service 517 to

automatically regulate the product temperature. The heat retention loop 520 is optionally used

leaves the pasteurizer/cooler 516.

The zone heater/cooler 521 is used to adjust the temperature of the product after it has

left the pasteurizer/cooler 516. The zone heater/cooler utilizes service water from the zone

heater/cooler hot/cold service 522. This service water circulates through the zone heater/cooler

by means of a zone heater/cooler service supply lines 523, and is used to further adjust the

temperature of the product to a desired temperature. The zone heater/cooler R.T.D. sensor 524

senses the temperature of the product leaving the pasteurizer/cooler and sends a signal 524A back

to the zone heater/cooler hot/cold service 522 to automatically regulate the product temperature.

The heat exchanger 526 is utilized during this entire process to help preserve the desired

product temperature. When the product reaches the proper temperature range (as set at the filler R.T.D. sensor 542), the filler divert valve 543 is automatically activated by the filler 3-way switch

544 to divert product into the filler 545.

Containers are now sent to filler 545 and filled with product. This process continues until

the end of the run, or until a product change.

4. Filler Line Product Recovery Procedure

Once the line tank goes empty, turn the balance/filler feed tank 3-way switch 505 to the

"off" position, thus turning off the line tank pump 310 in the line tank product recovery module

248 (See FIGS. 2 and 3). Send compressed air/gas 305 through the product recovery module

first check valve 306 (in line tank product recovery module 248), preferably for approximately

15 seconds and at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe

having a nominal diameter of 2 inches, or as required to evacuate substantially all the product

from that portion of the product line 304 preceding the pump 310 and to push the product past

the product recovery module second check valve 314. Immediately send compressed air/gas 312

through the second check valve 314 (in line tank product recovery module 248), preferably for

approximately 20 seconds at a flow rate approximately equivalent to 80 c.f.m. within a schedule

40 steel pipe having a nominal diameter of 2 inches, or as required to evacuate the remainder of

product from the product line 304, line tank product line 250, and into the balance/filler feed tank

503.

When the balance/filler feed tank 503 is nearly empty of product (approximately 50 gallons

remaining or at the filler operator's discretion), open the filler return tank second divert valve 559

to divert product through the filler return tank second divert valve product line 560, and through

the heat exchanger second check valve 574 so that the product joins the product flowing through

the balance/filler feed tank product line 501. Send compressed air/gas 562 through filler return tank third check valve 563,a preferably for approximately 30 seconds at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, or as required to evacuate the remainder of product from the balance/filler feed tank product return line 573, the balance/filler

feed tank product return line heater/cooler 564, the balance/filler feed tank product return line

heater/cooler sight glass 567, the balance/filler feed tank product return line heater/cooler divert

valve 568, and into the balance/filler feed tank 503.

When the balance/filler feed tank 503 goes completely empty, turn the balance/filler feed

tank pump 512 off. Close the balance/filler feed tank valve 508. Immediately send compressed

air/gas 509 through balance/filler feed tank first check valve 510, preferably for approximately 30 seconds at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, or as required to evacuate the remainder of product from the balance/filler feed tank product line 501, the balance/filler feed tank divert valve 511, the

balance/filler feed tank pump 512, the balance/filler feed tank second check valve 514, the

balance/filler feed tank "T" valve 515, the pasteurizer/cooler 516, the pasteurizer/cooler R.T.D.

sensor 519; the heat retention loop 520, the zone heater/cooler sight glass 525, the zone

heater/coolers 521 , the zone heater/cooler R.T.D. sensor 524, the heat exchanger first divert valve

527 (opened to heat exchanger product line 541), through the heat exchanger sight glass 528, into

the heat exchanger 526, through the heat exchanger second divert valve 535, and into the filler return tank 548.

Using sight glass 528, or alternately an automatic senor device, verify that substantially

all of the remaining product in the heat exchange product line 541 has been pushed into the filler

return tank 548. Once this occurs, turn off compressed air/gas 513 and close the balance/filler feed tank second check valve 514. Immediately send water 572 through the balance/filler feed

tank "T" valve 515 and into the balance/filler feed tank product line 501, preferably at a flow rate approximately equivalent to 60 g.p.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, within a schedule 40 steel pipe having a nominal diameter of 2 inches, within a

schedule 40 steel pipe having a nominal diameter of 2 inches, or as required for the water 572 to

simulate the flow of product through the pasteurizer/cooler 516 and heat exchanger 526. Open

the heat exchanger second divert valve 535 to the heat exchanger drain 536.

The water 572 is now being heated or cooled to the desired temperature by the

pasteurizer/cooler 516 and/or the zone heater/cooler 521. The temperature adjusted water 572

now becomes service water in the heat exchanger 526 to maintain or adjust the temperature of

the remainder of product being circulated through the heat exchanger 526, filler 545 and filler return tank 548.

As the quantity of product becomes depleted, slow down the filler 545 and continue filling containers with product, which is maintained "at temperature" by circulating both product and

the temperature adjusted water 572 through the heat exchanger 526. Continue slowing down the filler 545 and filling containers until the filler return tank 548

is empty, as verified by use of the filler return tank sight glass 550, or alternately verified by use

of a suitable automatic sensory device. Turn the filler return tank 3-way switch to the "off" position, thus deactivating the filler return pump 556. Send low volume air/gas 552 through the

filler return tank first check valve 553, preferably at an approximate pressure of 15 to 20 p.s.i.,

or as required to evacuate the remainder of product from the filler return tank product line 551,

filler return tank first divert valve 554, filler return tank pump 556, filler return tank second check

valve 558, filler return tank second divert valve 559, into the filler return tank second divert valve product line 560, through the sight glass 561, and through the heat exchanger second check valve

574 into the balance/filler feed tank product line 501, then into the heat exchanger 526, filler

R.T.D. sensor 542, filler divert valve 543, and into the filler 545. Use low volume air/gas 552 to

continue pushing all remaining product through the system into the filler 545 and into the

containers being filled.

The use of the temperature adjusted water 572 circulating through the heat exchanger 526

has maintained all the remaining evacuated product "at temperature" so that substantially all of

the remaining product can be placed into containers at the filler 545 at approved temperature.

the filler line has been placed into containers. Turn off water 572. Turn hot/cold service 517 off.

Repeat the entire procedures detailed in Section III.B. l above, titled 'Tiller Line Rinse

Procedure," and in Section II.B.2, titled 'Tiller Line Rinse Water Air/Gas Evacuation Procedure."

The filler line depicted in FIG. 5 is now ready for a product change, or ready to be shut down.

C. EXAMPLE 3 (FIGS. 6, 2C AND 2)

1. Filler Line Rinse Procedure

Using balance/filler feed tank spray ball water 606, pre-rinse a balance/filler feed tank 603

and allow the rinse water to drain through a balance/filler feed tank second valve 608, a

balance/filler feed tank first check valve 610, and a balance/filler feed tank divert valve 611

opened into a balance/filler feed tank drain 669. Using clean, fresh, safe filler return tank spray

ball water 649, pre-rinse a filler return tank 648, and allow the rinse water to drain through a filler

return tank first check valve 653 and a filler return tank first divert valve 654 into a filler return

tank drain 655. Verify that the line tank second valve 246 (FIG. 2) is closed. Send water 302 (FIG. 3)

through the product line 304 (FIG. 3) and all the equipment identified in the line tank product

recovery module 248 (See FIGS. 2 and 3) and into the line tank product line 250 (FIG. 2),

through a balance/filler feed tank first valve 602, and into a balance/filler feed tank 603. Fill the

balance/filler feed tank approximately 50% to 75% full, verifying the fill level by use of a

balance/filler feed tank sight glass 607 or other suitable automatic sensory device. Open the

balance/filler feed tank second valve 608 and allow water 302 to flood through a balance/filler

feed tank product line 601 into the balance/filler feed tank first check valve 610, the balance/filler

feed tank divert valve 611, and into a balance/filler feed tank pump 612, thus priming the

balance/filler feed tank pump. Activate the balance/filler feed tank pump and pump water 302

forward into the following equipment interconnected by the balance/filler feed tank product line

601: a balance/filler feed tank second check valve 614, a balance/filler feed tank "T" valve 615

, a pasteurizer/cooler 616, a pasteurizer/cooler R.T.D. sensor 619, a heat retention loop 620, a

zone heater/cooler sight glass 625, zone heater/coolers 621, a zone heater/cooler R.T.D. sensor

624, a heat exchanger first check valve 629, a heat exchanger 626, a heat exchanger first R.T.D.

sensor 628, a filler R.T.D. sensor 642, a filler divert valve 643 and into a filler 645.

For approximately 15 seconds open the filler divert valve 643 to divert water 302 into a

filler bypass product line 646, which joins a filler overflow line 647 downstream from the filler

645, in order to rinse the filler bypass product line. Then reopen the filler divert valve to the

filler. Continue pumping water 302 through the balance/filler feed tank product line 601 into

the filler, As water 302 floods through the filler, water 302 will continue to flow through the filler

overflow line 647 and into the filler return tank 648. Open the filler return tank first check valve 653 so that water 302 floods out through a

filler return tank product line 651 into the filler return tank first divert valve 654, and into a filler

return tank pump 656, thus priming the filler return tank pump. Turn a filler return tank 3-way

switch 671 to the "on" position to activate the filler return tank pump and pump water 302

through the product line 651 into a filler return tank second check valve 658, filler return tank

sight glass 680, a filler return tank second divert valve 659 which is opened to a balance/filler feed

tank return product line 673, through a filler return tank third check valve 663, a balance/filler

feed tank product return line heater/cooler 664, a balance/filler feed tank product return line

heater/cooler sight glass 667, a balance/filler feed tank product return line heater/cooler divert

valve 668, and into the balance/filler feed tank 603.

For approximately 15 seconds, open the filler return tank second divert valve 659 so that

water 302 is diverted through a filler return tank second divert product line 660, through a filler

return tank second divert valve sight glass 661, a heat exchanger third check valve 675, and then

into the balance/filler feed tank product line 601 at a point between the heat exchanger 626 and

the heat exchanger first check valve 629. Then reopen the divert valve 659 to the balance/filler

feed tank return product line 673.

Turn off all system pumps; namely, the balance/filler feed tank pump 612 and the filler

return tank pump 656. Open all divert-to-drain valves to their respective drains; namely, the

balance/filler feed tank divert valve 611 to the balance/filler feed tank drain 669, the filler return

tank first divert valve 654 to the filler return tank drain 655, and the heater/cooler divert valve 668

to the balance/filler feed tank drain 669. Allow the entire system to drain as much rinse water as

possible from the filler lines and equipment into the open drains. The entire filler line system is now rinsed. 2. Filler Line Rinse Water Compressed

Air/Gas Evacuation Procedure

In consecutive sequence, send approximately 30 seconds of compressed air/gas at a flow

diameter of 2 inches, through each of the following check valves:

a. Compressed air/gas 305 through product recovery module first check

valve 306 (FIG. 3) in the line tank produce recovery module 248 (FIG. 2),

b. Compressed air/gas 312 through product recovery module second check

valve 314 (FIG. 3) in line tank produce recovery module 248 (FIG. 2).

c. Compressed air/gas 609 through the balance/filler feed tank first check

valve 610.

d. Compressed air/gas 613 through the balance/filler feed tank second check

valve 614 for approximately 45 seconds, making sure to open the filler

divert valve 643 for approximately 15 seconds to clear the filler bypass

product line 646 of rinse water.

e. Compressed air/gas 652 through the filler return thank first check valve

653

f. Compressed air/gas 657 through the filler return tank second check valve

658 for approximately 45 seconds, making sure to open the divert valve

659 for approximately 15 seconds to clear the filler return second divert

valve product line 660 of rinse water. g. Compressed air/gas 662 through the filler return tank third check valve

663.

residual rinse water and thus remains usable. No product is wasted in order to expel used rinse water from the filler line. At this stage of the process, the filler line is now rinsed, the rinse water

has been expelled, and the filler line is ready for the introduction of product.

3. Filler Line Product Transfer

Reopen all divert-to-drain valves to their respective product lines; namely, the

balance/filler feed tank divert valve 611 to the product line 601, the filler return tank first divert

valve 654 to the product line 651, and the heater/cooler divert valve 668 to the balance/filler feed

tank return product line 673. Close the balance/filler feed tank second valve 608.

Open the line tank second valve 246 (FIG. 2) so that product flows into the line tank

product line 250, and through the product line 304 of the line tank product recovery module 248

(FIGS. 2 and 3) into the product recovery module "T" valve 303 (FIG. 3), the product recovery

module first check valve 306 (FIG. 3), and into the product recovery module pump 310. Product

thus primes the pump (FIG. 3).

Turn a balance/filler feed tank 3-way switch 605 to the "auto" position, so that the switch

responds to a signal input 604a from a balance/filler feed tank high/low probe 604. The

balance/filler feed tank high/low probe will signal the balance/filler feed tank 3-way switch to

activate the line tank pump 310 if the product level in the balance/filler feed tank 603 drops below

a predetermined setting, and will signal the balance/filler feed tank 3-way switch to turn the line

tank pump off if the product level rises above a predetermined setting in the balance/filler feed tank. Since the balance/filler feed tank is presently empty of both product and rinse water, turning the balance/filler feed tank 3-way switch to the "auto" position will activate the line tank pump and fill the balance/filler feed tank to a predetermined level.

Open the balance/filler feed tank second valve 608 and allow product to flood through the

balance/filler feed tank product line 601 into the balance/filler feed tank first check valve 610, the

balance/filler feed tank divert valve 611, and into the balance/filler feed tank pump 612, thus priming the balance/filler feed tank pump. Activate the balance/filler feed tank pump and pump

product forward into the following equipment interconnected by the balance/filler feed tank product line 601: the balance/filler feed tank second check valve 614, the balance/filler feed tank

"T" valve 615, the pasteurizer/cooler 616, the pasteurizer/cooler R.T.D. sensor 619; the heat

retention loop 620, the zone heater/cooler sight glass 625, zone heater/coolers 621, the zone

heater/cooler R.T.D. sensor 624, the heat exchanger first check valve 629, the heat exchanger

626, the heat exchanger R.T.D. sensor 628, filler R.T.D. sensor 642, the filler divert valve 643

opened to the filler bypass product line 646, through the filler overflow line 647, and into the filler return tank 648.

Turn a filler 3-way switch 644 to the "auto" position, so that the switch responds to a

signal input 642a from the filler R.T.D. sensor 642. The filler R.T.D. sensor will signal the filler

3-way switch to activate the filler divert valve 643 to divert product to the filler bypass product

line 646 if the product temperature is outside of a predetermined range of high and low temperature. Too low a temperature could render some products unsafe due to a lack of effective pasteurization. Too high a temperature could result in excessively hot product damaging plastic containers which may be used in some situations. For other products a cold temperature is desired. For example, carbonated beverages must be bottled at cold temperatures to maintain proper carbonation. The filler R.T.D. sensor 642 will signal the filler 3-way switch 644 to

activate the filler divert valve 643 (by means of the filler 3-way switch signal 644a) to divert

product to the filler 645 if the product temperature is within a predetermined range of high and

low temperature, i.e. when the product is "at temperature." Since it takes several minutes for the

product temperature to be adjusted to the proper level by the pasteurizer/cooler 616 and/or the

zone heater/cooler 621, turning the filler 3-way switch 644 to the "auto" position at this time will

activate the filler divert valve to divert product to the filler bypass product line 646. Until the

product is "at temperature," it will continue to flow through the heat exchanger second divert

product line, and then into the filler overflow line 647, and then into the filler return tank 648.

Open the filler return tank first check valve 653 so that product flows out through the filler return

tank product line 651 into the filler return tank first divert valve 654, and into the filler return tank

pump 656, thus priming the filler return tank pump.

Turn a filler return tank 3-way switch 671 to the "auto" position, so that the switch

responds to a signal input 670a from a balance/filler feed tank high/low probe 670. The filler

return high/low probe will signal the filler return tank 3-way switch to activate the filler return

tank pump 656 when the product level in the filler return tank 648 rises to a predetermined level,

and will signal the filler return tank 3-way switch to turn the line tank pump 310 off if the product

level falls below a predetermined setting in the filler return tank. Since the filler return tank is

presently filling with product, turning the balance/filler feed tank 3-way switch 605 to the "auto"

position will activate the filler return tank pump 656 when the product in the filler return tank

reaches the predetermined level in the tank. Once the filler return tank pump activates, the

product is pumped through the product line 651 into the filler return tank second check valve 658,

the filler return tank second divert valve 659 which is opened into the balance/filler feed tank return product line 673, the filler return tank third check valve 663, the heater/cooler 664, the

heater/cooler sight glass 667, the heater/cooler divert valve 668 which is opened to the

balance/filler feed tank return product line 673, and into the balance/filler feed tank 603.

Balance/filler feed tank product return line heater/cooler 664 is used to adjust the

temperature of product being returned back into the balanced/filler feed tank. The heater/cooler

adjusts the temperature of the product flowing through it by means of a balance/filler feed product

return line heater/cooler hot/cold service 665, which circulates service water through the

heater/cooler by means of a balance/filler feed product return line heater/cooler hot/cold service

supply line 666. For those products which are placed into containers while warm or hot, the

return line heater/cooler 664 is used is lower the temperature of the product returning to the

balance/filler feed tank 603 to approximately match the temperature of the product flowing into

the balance/filler feed tank from the line tank. For those products which are placed into containers

while cool or cold, the return line heater/cooler is used is raise the temperature of the product returning to the balance/filler feed tank to approximately match the temperature of the product

flowing into the balance/filler feed tank from the line tank.

Product is now flowing completely through the filler line depicted in FIG. 6, except for

the filler 645. Set the temperature at the controller (not shown) for the hot/cold service 617. The

pasteurizer/cooler 616 utilizes service water from the hot/cold service. This service water

circulates into the pasteurizer/cooler through a hot/cold service supply line 618a, a

pasteurizer/cooler service divert valve 627, and a pasteurizer/cooler service intake line 627a,

through the pasteurizer/cooler, and back to the hot/cold service by means of a pasteurizer/cooler

service return line 618b and a pasteurizer/cooler check valve 636. The service water supplied by the hot/cold service 617 through the pasteurizer/cooler 616

is used to adjust the temperature of the product to the desired temperature. The

pasteurizer/cooler R.T.D. sensor 619 senses the temperature of the product leaving the

pasteurizer/cooler and sends a signal 619a back to the hot/cold service to automatically regulate

the product temperature at the desired setting. The heat retention loop 620 is optionally used to

help maintain the temperature of the product for an extended period of time after the product

leaves the pasteurizer/cooler 616.

The zone heater/cooler 621 is used to adjust the temperature of the product after it has

left the pasteurizer/cooler 616. The zone heater/cooler utilizes service water from the zone

heater/cooler hot/cold service 622. This service water circulates through the zone heater/cooler

by means of a zone heater/cooler service supply lines 623, and is used to further adjust the

temperature of the product to a desired temperature. The zone heater/cooler R.T.D. sensor 624

senses the temperature of the product leaving the pasteurizer/cooler and sends a signal 624a back

to the zone heater/cooler hot/cold service 622 to automatically regulate the product temperature.

The heat exchanger 626 is utilized during this entire process to help preserve the desired

product temperature. When the product reaches the proper temperature range (as set at filler

R.T.D. sensor 642), the filler 3-way switch 644 sends a signal 644a to the filler divert valve 643

to divert product into the filler 645.

Containers are now sent to the filler 645 and filled with product. This process continues

until the end of the run, or until a product change.

4. Filler Line Product Recovery Procedure Once the line tank goes empty, turn the balance/filler feed tank 3-way switch 605 to the

248 (See FIGS. 2 and 3). Send approximately 15 seconds of compressed air/gas 305 at a flow

diameter of 2 inches, through the product recovery module first check valve 306 (in line tank

product recovery module 248) to evacuate substantially all the product from that portion of the

product line 304 preceding the product recovery module pump 310 and past the second check

valve 314. Send approximately 20 seconds of compressed air/gas 312 at a flow rate

of 2 inches, through the product recovery module second check valve 314 (in line tank product

recovery module 248) to evacuate the remainder of product from the product line 304, the line

tank product line 250, and into the balance/filler feed tank 603.

When the balance/filler feed tank 603 is nearly empty of product (approximately 50 gallons

remaining or at the filler operator's discretion), slow down the balance/filler feed tank pump 612.

Also slow down the filler return tank pump 656, and open the filler return tank second divert

valve 659 to divert product through the filler return tank second divert valve product line 660,

so that the product joins the product flowing through the balance/filler feed tank product line 601

at a point between the heat exchanger check valve 629 and the heat exchanger 626.

Send approximately 30 seconds of compressed air/gas 662 at a flow rate approximately

equivalent to 80 c.f.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches,

through the filler return tank third check valve 663 to evacuate the remainder of product from the

balance/filler feed tank return product line 673, the heater/cooler 664, the heater/cooler sight glass

667, the heater/cooler divert valve 668, and into the balance/filler feed tank 603. When the balance/filler feed tank 603 goes completely empty, turn off the balance/filler

feed tank pump 612. Close the balance/filler feed tank second valve 608.

Open the pasteurizer/cooler divert valve 627 to a heat exchanger service intake line 627b.

Direct service water from the hot/cold service 617 through a hot/cold service supply line 618a,

the pasteurizer/cooler divert valve 627, the heat exchanger service intake line 627b, and into the

heat exchanger 626. The service water circulates through heat exchanger and then returns to the

hot/cold service through a heat exchanger service return line 641 and heat exchanger second

check valve 674. At this point, the hot/cold service is solely servicing the heat exchanger 626,

and not the pasteurizer/cooler 619. The heat exchanger is now used to maintain or adjust the

temperature of the product to the desired setting while all of the remaining product in the filler

line is pumped or evacuated into the filler 645 and placed into containers.

Temporarily stop sending containers to the filler 645. Open the filler divert valve 643 to

the filler bypass line 646. Send approximately 10 seconds of compressed air/gas 609 at a flow

diameter of 2 inches, through the balance/filler feed tank first check valve 610 to evacuate the

residual product forward through the product line 601, the divert valve 611, and the balance/filler

feed tank pump 612, and past the balance/feed filler tank check valve 614. Immediately send

approximately 60 seconds of compressed air/gas 613 at a flow rate approximately equivalent to

80 c.f.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, through the

balance/filler feed tank first check valve 614 to evacuate the remainder of product from the

balance/filler feed tank product line 601, the balance/filler feed tank "T" valve 615, the

pasteurizer/cooler 616, the pasteurizer/cooler R.T.D. sensor 619; the heat retention loop 620, the zone heater/cooler sight glass 625, zone heater/coolers 621, the zone heater/cooler R.T.D. sensor

624, the heat exchanger first check valve 629, and into the heat exchanger 626.

Set the filler 3-way switch 644 back to "auto" so that product is diverted back into the

filler 645 once the product returns to "temperature." Once product begins flowing back into the

filler, restart the filler at a slow speed and restart sending containers to the filler. The filler return

tank pump 656 is now acting as the container filler feed pump, and the filler return tank 648 is

functioning as both the filler return tank and the filler feed tank. As the total quantity of product

becomes depleted, slow down the filler 645 as necessary and continue filling containers with

product, which is being maintained "at temperature" by circulating both product and service water

through the heat exchanger 626.

Continue slowing down the filler 645 and filling containers until the filler return tank 648

is empty, as verified by use of the filler return tank sight glass 650, or alternately verified by use

of any other suitable sensory device. Turn the filler return tank 3-way switch 671 to the "off"

position, thus deactivating the filler return pump 656. Send low volume compressed air/gas 652,

at an approximate flow rate of 15 to 20 p.s.i. through the filler return tank first check valve 653

to evacuate the remainder of product through the filler return tank product line 651, the filler

return tank first divert valve 654, the filler return tank pump 656, the filler return tank second

check valve 658, the filler return tank second divert valve 659, the filler return tank second divert

valve product line 660, the heat exchanger sight glass 661, the heat exchanger third check valve

675, the balance/feed tank product line 601, the heat exchanger 626, the heat exchanger R.T.D.

sensor 628, the filler R.T.D. sensor 642, the filler divert valve 643, and into the filler 645. Use

low pressure compressed air/gas 652 to continue pushing all remaining product through the

system into the filler 645 and into the containers being filled. The use of temperature adjusted service water diverted by pasteurizer/cooler service divert

valve 627 to circulate through the heat exchanger 626 has maintained all the remaining evacuated

product "at temperature" so that substantially all of the remaining product can be placed into

containers at the filler 645 at approved temperature.

the filler line has been placed into containers. Turn off the hot/cold service 617. Repeat the entire

rinse procedure described in Section III.C.l above, titled 'Tiller Line Rinse Procedure," and the

rinse water air/gas evacuation procedure described in section III.C.2. above, titled, 'Tiller Line Rinse Water Air/Gas Evacuation Procedure." The filler line depicted in FIG. 6 is now ready for

a product change, or ready to be shut down.

D. EXAMPLE 4 (FIGS. 7, 2D AND 2)

1. Filler Line Rinse Procedure

Using balance tank spray ball water 706, pre-rinse a balance tank 703 and allow the rinse

water to drain through a balance tank second valve 708, a balance tank first check valve 710, and

a balance tank divert valve 711 into a balance tank drain 769. Using filler feed tank spray ball

water 731, pre-rinse a filler feed tank 730 and allow the rinse water to drain through a filler feed

tank first check valve 734 and a filler feed tank divert valve 735 into a filler feed tank drain 736.

Using filler return tank spray ball water 749, pre-rinse a filler return tank 748, and allow the rinse

water to drain through a filler return tank first check valve 753 and a filler return tank first divert

valve 754 into a filler return tank drain 755.

Verify that the line tank valve second 246 (FIG. 2) is closed. Send water 302 (FIG. 3)

recovery module 248 (See FIGS. 2 and 3) and into the line tank product line 250 (FIG. 2), through the balance tank first divert valve 702, and into the balance tank 703. Fill the balance

tank 703 approximately 50% to 75% full, verifying the fill level by use of a balance tank sight

glass 707, or alternately a suitable automatic sensory device. Open the balance tank first valve

708 and allow water 302 to flood through the balance tank product line 701 into a balance tank

first check valve 710, a balance tank divert valve 711, and into a balance tank pump 712. The

rinsing water 302 thus primes the balance tank pump.

Activate the balance tank pump 712 and pump water 302 forward into the following

equipment interconnected by the balance tank product line 701 : a balance tank second check valve

714; a balance tank "T" valve 715; a pasteurizer/cooler 716; a pasteurizer/cooler R.T.D. sensor

719; a heat retention loop 720; zone heater/coolers 721; a zone heater/cooler R.T.D. sensor 724;

a zone heater/cooler sight glass 725; a zone heater/cooler divert valve 727, and into the filler feed

tank 730. Continue pumping water 302 through the balance tank product line 701 until water

completely fills the filler feed tank 730.

Water 302 then overflows through a filler feed tank overflow line 741 into a filler return

tank 748. Water 302 also flows through a filler feed tank first check valve 734 through a filler

feed tank product line 740 into a filler feed first check valve 734, a filler feed tank first divert

valve 735, and then into a filler feed tank pump 737, thus priming the filler feed tank pump.

740 and into a filler feed tank second check valve 739, a filler feed tank second divert valve 784,

a filler feed tank third check valve 785, a filler product line 787, a filler R.T.D. sensor 742, a filler

divert valve 743, and into a filler 745. Preferably, rinse the filler 745 for approximately 10

seconds, then open the filler divert valve 743 so that water 302 is diverted into a filler bypass

product line 746, then into a filler overflow return line 747, and then into the filler return tank 748. Open the filler feed tank second divert valve 784 to divert water 302 into a blowdown line

786 and the filler return tank 748 for preferably approximately 10 seconds to rinse out the

blowdown line 786. Once the blowdown line 786 has been rinsed, re-open the second divert

valve 784 to divert water 302 back into the filler feed tank product line 740. Water 302

flows through a filler return tank first check valve 753 into a filler return tank product line 751,

through a filler return tank first check valve 753, a filler return tank first divert valve 754, and into

a filler return tank pump 756, thus priming the filler return pump. Turn a filler return tank 3-way

switch 771 to the "on" position to activate the filler return tank pump and pump water 302

through the product line 751 into a filler return tank second check valve 758, a filler return tank

second divert valve 759 (open to a balance tank product return line 773), through the balance tank

product return line 773, a filler return tank third check valve 763, a balance tank product return

line heater/cooler 764, a balance tank product return line heater/cooler sight glass 767, a balance

tank product return line heater/cooler divert valve 768, and into the balance tank 703.

Preferably for approximately 15 seconds, open the filler return tank second divert valve

759 so that water 302 is diverted through a heat exchanger product line 760, a heat exchanger

sight glass 761, the heat exchanger 726, a filler product line 787, a heat exchanger R.T.D. sensor

788, a filler check valve 789, the filler R.T.D. sensor 742, the filler divert valve 743, and into the

filler 745. Then, re-open the filler return tank third divert valve 759 to send water 302 back

through the balance tank product return line 773 to complete rinsing the product line 773 and the

equipment it interconnects.

Turn off all system pumps; namely, the balance tank pump 712, the filler feed tank pump

737, and the filler return tank pump 756. Open all divert-to-drain valves to their respective

drains; namely, the balance tank divert valve 711 to the balance tank drain 769, the zone heater/cooler divert valve 727 to a zone heater/cooler drain 729, filler feed tank divert valve 735

to the filler feed tank drain 736, the filler return tank first divert valve 754 to the filler return tank

drain 755, and balance tank product return line heater/cooler divert valve 768 to balance tank

drain 769. The entire filler line system is now rinsed.

2. Filler Line Rinse Water Air/Gas Evacuation Procedure In consecutive sequence, send approximately 30 seconds of compressed air/gas at a flow

rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, through each of the following check valves:

a. Compressed air/gas 305 through the product recovery module first check

valve 306 (FIG. 3) in the line tank produce recovery module 248 (FIG. 2).

b. Compressed air/gas 312 through the product recovery module second

check valve 314 (FIG. 3) in the line tank produce recovery module 248

(FIG. 2).

c. Compressed air/gas 709 through the balance tank first check valve 710.

d . Compressed air/gas 713 through the balance tank second check valve 714.

e. Compressed air/gas 733 through the filler feed tank first check valve 734.

f Compressed air/gas 738 through the filler feed tank second check valve

739 for approximately 60 seconds, making sure to open the filler feed tank

second divert valve 784 for approximately 15 seconds to clear the

blowdown line 786 of rinse water, and to open the filler divert valve 743

for approximately 15 seconds to clear the filler bypass line 746 and the

filler overflow return line 747 of rinse water. g. Compressed air/gas 752 through the filler return tank first check valve

753.

h. Compressed air/gas 757 through the filler return tank second check valve

758 for at least approximately 45 seconds, making sure to open the third

divert valve 759 for at least approximately 15 seconds to clear the heat

exchanger product line 760, the heat exchanger 726, and the filler product

line 787 of rinse water.

i. Compressed air/gas 762 through filler return tank third check valve 763.

in the filler line in this fashion evacuates substantially all of the rinse water in the entire filler line.

Now, when product flows through the filler line, substantially all of the product remains undiluted

by residual rinse water and thus remains usable. No product is wasted in order to expel used rinse water from the filler line. At this stage of the process, the filler line is now rinsed, the rinse water

is expelled, and the filler line is ready for the introduction of product.

3. Filler Line Product Transfer

divert valve 711 to the balance tank product line 701, the zone heater/cooler divert valve 727 to

the product line 701, the filler feed tank first divert valve 735 to the filler feed tank product line

740, the filler feed tank second divert valve 784 to the product line 740, the filler divert valve 743

to the filler product line 787, the filler return tank first divert 754 to the filler return tank product

line 751, and the balance tank heater/cooler divert valve 768 to the balance tank return product

line 773. Close the balance tank first valve 708. Open the line tank second valve 246 (FIG. 2)

so that product flows into the line tank product line 250, and through the product line 304 of the line tank product recovery module 248 (FIGS. 2 and 3) into the product recovery module "T"

valve 303 (FIG. 3), the product recovery module first check valve 306 (FIG. 3), and into the

product recovery module pump 310. The product thus primes the product recovery module pump

310 (FIG. 3).

Turn a balance tank 3-way switch 705 to the "auto" position, so that the switch responds

to a signal input 704a from a balance tank high/low probe 704. The high/low probe will signal

the 3-way switch 705 to activate the line tank pump 310 if the product level in the balance tank

703 drops below a predetermined setting, and will signal the 3-way switch to turn the line tank

pump off if the product level rises above a predetermined setting in the balance tank. Since the

balance tank 703 is presently empty of both product and rinse water, turning the 3-way switch

705 to the "auto" position will activate the line tank pump 310 and fill the balance tank to a

predetermined level.

Open the balance tank first valve 708 and allow product to flood through the balance tank

product line 701 into the balance tank first check valve 710, the balance tank divert valve 711,

and into the balance tank pump 712, thus priming pump 712. Activate pump 712 and pump

product forward into the following equipment interconnected by the balance tank product line

701: the balance tank second check valve 714; the balance tank second valve 715; the

pasteurizer/cooler 716; the pasteurizer/cooler R.T.D. sensor 719; the heat retention loop 720; the

zone heater/coolers 721; the zone heater/cooler R.T.D. sensor 724; the zone heater/cooler sight

glass 725; the zone heater/cooler divert valve 727, and into the filler feed tank 730. Product will

then flow through the filler feed tank product line 740, the filler feed tank first check valve 734,

the filler feed return tank first divert valve 735, and into the filler feed tank pump 737, thus

priming the pump 737. Turn a filler 3-way switch 744 to the "auto" position, so that the switch responds to a

signal input 742a from filler R.T.D. sensor 742. The R.T.D. sensor will signal the 3-way switch

744 to send a filler 3 -way-switch signal 744a to activate the divert valve 743 to divert product

to the filler bypass product line 746 if the product temperature is outside of a predetermined range

of high and low temperature. Too low a temperature could render some products unsafe due to

a lack of effective pasteurization. Too high a temperature could result in excessively hot product

damaging plastic containers which may be used in some situations. For other products a cold

temperature is desired. For example, carbonated beverages must be bottled at cold temperatures

to maintain proper carbonation. The filler R.T.D. sensor 742 will signal the filler 3-way switch

744 to activate the filler divert valve 743 to divert product to the filler 745 if the product

temperature is within a predetermined range of high and low temperature, i.e. when the product

is "at temperature." Since it takes several minutes for the product temperature to be adjusted to

the proper level by the pasteurizer/cooler 716 and/or the zone heater/cooler 721, turning the filler

3-way switch 744 to the "auto" position at this time will activate the filler divert valve 743 to

divert product to the filler bypass product line 746.

Activate the pump 737 and pump the product through the filler feed tank product line 740

and into the filler feed tank second check valve 739, the filler feed tank second divert valve 784,

the filler feed tank third check valve 785, the filler product line 787, the filler R.T.D. sensor 742,

the filler divert valve 743, and into the filler bypass line 746. Product will continue to flow into

the filler bypass line 746 until the filler R.T.D. sensor 742 senses that product temperature is

within the predetermined range, or "at temperature." The process of adjusting the product

temperature takes some time. Until the product is "at temperature," it will continue to flow through the filler bypass

product line 746, and then into the filler overflow product line 747, and then into the filler return

tank 748. Product will then flow into the filler return tank product line 751, through the filler

return tank first check valve 753, the filler return tank first divert valve 754, and into the filler

return tank pump 756, thus priming pump 756.

Turn a filler return tank 3-way switch 771 to the "auto" position, so that the switch

responds to a filler return tank high/low probe signal input 770a from a filler return tank high/low

probe 770. The filler return high/low probe will signal the 3-way switch 771 to send a filler return

tank 3-way switch signal 771a to activate the filler return tank pump 756 when the product level

in the filler return tank rises to a predetermined level, and will signal the filler return tank 3-way

switch to turn the filler return tank pump 756 off if the product level falls below a predetermined

setting in the filler return tank 748. Since filler return tank is presently filling with product,

turning the filler return tank 3-way switch 705 to the "auto" position at this stage of the process

will activate the pump 756 when the product in the filler return tank 748 reaches the

predetermined level in the tank,

Once the pump 756 activates, the product is pumped through the product line 751 into

the filler return tank second check valve 758, the filler return tank second divert valve 759 (open

to the balance tank product return line 773), the balance tank product return line 773, the filler

return tank third check valve 763, the balance tank product return line heater/cooler 764, the

balance tank heater/cooler sight glass 767, the balance tank heater/cooler divert valve 768, and

into the balance tank 703.

Balance/filler feed tank product return line heater/cooler 764 is used to adjust the

temperature of product being returned back into the balanced/filler feed tank. The heater/cooler adjusts the temperature of the product flowing through it by means of a balance/filler feed product

return line heater/cooler hot/cold service 765, which circulates service water through the

supply line 766. For those products which are placed into containers while warm or hot, the

return line heater/cooler 764 is used is lower the temperature of the product returning to the

balance/filler feed tank 703 to approximately match the temperature of the product flowing into

while cool or cold, the return line heater/cooler is used is raise the temperature of the product

returning to the balance/filler feed tank to approximately match the temperature of the product flowing into the balance/filler feed tank from the line tank.

Product is now flowing completely through the entire filler line depicted in FIG. 7, except

for the filler 745. Set the temperature at the controller (not shown) for a pasteurizer/cooler

hot/cold service 717. The Pasteurizer/cooler 716 utilizes service water from the

pasteurizer/cooler hot/cold service 717. While product is flowing through the pasteurizer/cooler

716, the service water from the hot/cold service 717 is diverted by a pasteurizer/cooler divert

valve 781 to flow through the pasteurizer/cooler 716 through the following product lines and

equipment: a pasteurizer/cooler hot/cold service supply line 790, the divert valve 781, a

pasteurizer/cooler service supply line 791, the pasteurizer/cooler 716, a pasteurizer/cooler return

line 793, a pasteurizer/cooler check valve 783, a pasteurizer/cooler hot/cold service return line

794, and to the hot/cold service 717. The service water thus flowing through the

pasteurizer/cooler 716 is used to adjust the temperature of the product to the desired temperature.

The pasteurizer/cooler R.T.D. sensor 719 senses the temperature of the product leaving the

pasteurizer/cooler and sends a pasteurizer/cooler R.T.D. signal 719a back to the hot/cold service 717 to automatically regulate the product temperature. The heat retention loop 720 is optionally

used to help maintain the temperature of the product for an extended period of time after the

product leaves the pasteurizer/cooler 716.

The zone heater/cooler 721 is used to adjust the temperature of the product after it has

left the pasteurizer/cooler 716. The zone heater/cooler utilizes service water from the zone

heater/cooler hot/cold service 722. This service water circulates through the zone heater/cooler

by means of a zone heater/cooler service supply lines 723, and is used to further adjust the

temperature of the product to a desired temperature. The zone heater/cooler R.T.D. sensor 724

senses the temperature of the product leaving the pasteurizer/cooler and sends a signal 724a back

to the zone heater/cooler hot/cold service 722 to automatically regulate the product temperature.

Once product flowing through the filler R.T.D. 742 reaches the desired temperature, the

filler 3-way switch 744 activates the filler divert valve 743 to divert product into the filer.

Containers are now sent to the filler 745 and filled with product. This process continues until the

end of the run, or until a product change.

4. Filler Line Product Recovery Procedure

Once the line tank goes empty, turn the balance tank 3-way switch 705 to the "off"

(See FIGS. 2 and 3). Send compressed air/gas 305 through check valve 306 (in line tank product

recovery module 248), preferably for approximately 15 to 20 seconds of at a flow rate

of 2 inches, or as required to expel substantially all the product through product line 304, past the

pump 310, and past the second check valve 314. Immediately send compressed air/gas 312 through check valve 314 (in line tank product recovery module 248), preferably for approximately

20 seconds at a flow rate approximately equivalent to 80 c.f.m. within a schedule 40 steel pipe

having a nominal diameter of 2 inches, to evacuate the remainder of product from the product

recovery module product line 304, the line tank product line 250, and into the balance tank 703.

When the balance tank 703 is nearly empty of product (approximately 50 gallons

remaining or at the filler operator's discretion), slow down the filler feed tank pump 737 to a very

slow flow rate. Open the filler return tank second divert valve 759 to divert product to the heat

exchanger product line 760, the heat exchanger sight glass 761, the heat exchanger 726, the filler

product line 787, the heat exchanger R.T.D. sensor 788, the filler check valve 789, the filler

R.T.D. 742, the filler divert valve 743, and into the filler 745.

Send compressed air/gas 762 through filler return tank third check valve 763, preferably

for approximately 30 seconds at a flow rate approximately equivalent to 80 c.f.m. within a

schedule 40 steel pipe having a nominal diameter of 2 inches, or as required to evacuate the

remainder of product from the balance tank return product line 773, the balance tank

heater/cooler 764, the balance tank heater/cooler sight glass 767, and the heater/cooler divert

valve 768, into the balance tank 703.

When the balance tank 703 goes completely empty, turn the balance tank pump 712 off.

Close the balance tank first valve 708. Immediately send compressed air/gas 709 through the

balance tank first check valve 710, preferably for approximately 10 seconds at a flow rate

of 2 inches, or as required to evacuate the remainder of product from the balance tank product

line 701 past the balance tank divert valve 711, the balance tank pump 712, and past the balance

tank second check valve 714. Immediately send compressed air/gas 713 through the balance tank second check valve 714, preferably for approximately 60 seconds at a flow rate approximately

equivalent to 80 c.f.m. within a schedule 40 steel pipe having a nominal diameter of 2 inches, or

as required to evacuate the remaining product from the balance tank product line 701, the balance

tank second valve 715, the pasteurizer/cooler 716, the pasteurizer/cooler R.T.D. sensor 719, the

heat retention loop 720, the zone heater/coolers 721, the zone heater/cooler R.T.D. sensor 724,

the zone heater/cooler sight glass 725, and the zone heater/cooler divert valve 727, into the filler

feed tank 730. Use the sight glass 725, or alternately an automatic sensory device, to verify that

substantially all the product has been evacuated into the filler feed tank 730. Once this occurs,

turn off compressed air/gas 713.

Now activate the pasteurizer/cooler divert valve 781 to divert service water into a heat

exchanger service supply line 795, so that the heat exchanger 726 can utilize service water from

the pasteurizer/cooler hot/cold service 717 to adjust or maintain the temperature the remaining

product flowing through the filler line system. During this stage of product recovery, the service

water from the hot/cold service 717 is flowing through the following lines and equipment: the

pasteurizer/cooler hot/cold service supply line 790, the divert valve 781, the heat exchanger

service supply line 795, the heat exchanger 726, a heat exchanger service return line 796, the heat

exchanger check valve 774, the pasteurizer/cooler hot/cold service return line 794, and to the

hot/cold service 717. The service water now flowing through the heat exchanger 726 is used to

adjust the temperature of the product to the desired temperature. Essentially, the heat exchanger

726 is now serving the same function as the pasteurizer/cooler 716 served during the transfer of

product from the line tank into the containers at the filler 745. The heat exchanger R.T.D. sensor

788 senses the temperature of the product leaving the heat exchanger 726 and sends a heat exchanger R.T.D. signal 788a back to the hot/cold service 717 to automatically regulate the

product temperature.

Slow down the filler 745 as the filler feed tank 730 begins to empty, as verified by a filler

feed tank sight glass 732, or alternately by a suitable automatic sensor. Activate the filler feed

tank second divert valve 784 to divert the remaining product into the blowdown line 786 and into

the filler return tank 748. At this stage in the recovery process, the filler return tank pump 756

becomes the filler feed pump.

Continue pumping product from the filler feed tank 730 until the tank goes empty. Turn

off the filler feed tank pump 737. Send compressed air/gas 733 through filler fed tank first check

valve 734, preferably for approximately 15 seconds at a flow rate approximately equivalent to 80

evacuate the remaining product through the filler feed tank product line 740, the filler feed tank

first divert valve 735, the filler feed tank pump 737, and past the filler feed tank second check

valve 739. Then immediately send compressed air/gas 738 through filler feed tank second check

valve 739, preferably for approximately 60 seconds at a flow rate approximately equivalent to 80

second divert valve 784, the blowdown line 786, and into the filler return tank 748.

Continue slowing down the filler 745 and filling containers until the filler return tank 748

is empty, as verified by the filler return tank sight glass 750, or alternately as verified by use of

a suitable automatic sensory device. Turn the filler return tank 3-way switch 771 to the "off"

position, thus deactivating the filler return tank pump 756. Send compressed air/gas 752

through the filler return tank first check valve 753, preferably for approximately 60 seconds at a low pressure of approximately 15 to 20 p s i , or as required to evacuate the remainder of product

from the filler return tank product line 751 and through the following product lines and

equipment the filler return tank first divert valve 754, the filler return tank pump 756, the filler

return tank second check valve 758, the filler return tank second divert valve 759 (open into the

heat exchanger product line 760), the heat exchanger product line 760, the heat exchanger sight

glass 761, the heat exchanger 726, the filler product line 787, the heat exchanger R T D sensor

788, the filler check valve 789, the filler R T D 742, the filler divert valve 743, into the filler 745,

and into the containers

When containers are filled with the last remaining product, substantially all of the product

originally introduced into the filler line has been placed into containers Turn off the compressed

air/gas 752. Turn the hot/cold service 717 off^* Repeat the entire rinse procedure described above

in Section III D 1 , titled 'Tiller Line Rinse Procedure," and the rinse water evacuation procedure described above in Section III D 2, titled 'Tiller Line Rinse Water Compressed Air/gas

Evacuation Procedure " The filler line depicted in FIG 7 is now ready for a product change, or

ready to be shut down

E. PREFERRED COMPONENTS FOR EXAMPLES 1, 2, 3, AND 4.

In a preferred embodiment of the preceding examples of container filling line recovery

systems, the following components have been utilized successfully, although other components

which function in an equivalent manner can also be used

Balance Tanks 403 and 703 316 stainless steel tanks manufactured by Balance/Filler Feed Tanks 503 and Mueller Tanks, Feldmeyer, and A P V

603 Crepaco have been successfully utilized

Filler Feed Tanks 430 and 730 Filler Return Tanks 448, 548, 648, and 748

Valves 402, 408, 502, 508, 602, and Defonex 316 stainless steel butterfly valves

608 Divert Valves 411, 427, 435, 454, Tri Clover 316 stainless steel pneumatic 459, 468, 511, 527, 535, 554, 559, divert valves 568, 611, 627, 654, 659, 668, 702, 711, 727, 784, 781, 754, 759, and 768

Check Valves (w gas/air) 410, 414, Tri Clover 316 stainless steel ball check 434, 439, 453, 458, 463, 510, 514, valves with a Tri Clover stainless steel 553, 558, 563, 610, 614, 653, 658, air/gas blow attachment. 663, 710, 714, 734, 739, 753, 758, and 763

Check Valves 529, 574, 629, 636, Tri Clover 316 stainless steel standard in-line 674, 675, 774, 783, 785, 789 check valve

Filler Divert Valves 443, 543, 643, Tri Clover 316 stainless steel pneumatic and 743 divert valves. Three positions: OFF - Normally closed to divert into filler bypass line, ON - open to filler, AUTO - controlled by filler R.T.D. and filler 3-way switch.

Pasteurizer/Coolers 416, 516, 616, 316 stainless steel pasteurizer/coolers and 716 manufactured by Thermaline, Feldmeyer, A.P.V. Crepaco have been successfully utilized

Heat Retention Loops 420, 520, 316 stainless steel heat retention loops 620, and 720 manufactured by Thermaline, Feldmeyer, A.P.V. Crepaco have been successfully utilized

Zone Heater/Cooler 421, 521, 621, 316 stainless steel zone heater/coolers and 721 manufactured by Thermaline, Feldmeyer, A.P.V. Crepaco have been successfully utilized.

Heater/Cooler (balance tank product 316 stainless steel heater/coolers return line) 464, 564, 664, and 764 manufactured by Thermaline, Feldmeyer,

A.P.V. Crepaco have been successfully utilized.

Sight Glasses 425, 428, 461, 467, 316 steel in-line sight glasses manufactured 525, 528, 561, 567, 625, 661, 667, by Jensen or Defonex. 680, 725, 728, 761, and 767 Sight Glasses 407, 432, 450, 507, Tank sight glasses integral to a tank, 550, 607, 650, 707, 732, and 750 manufactured by Thermaline, Feldmeyer, A.P.V. Crepaco have been successfully utilized.

Heat Exchanger 426, 526, 626, and 316 stainless steel heat exchanger, in triple 726 tube, double tube and plate pack configurations, manufactured by Thermaline, Feldmeyer, A.P.V. Crepaco have been successfully utilized.

R.T.D. sensors 419, 424, 442, 519, Resistive Thermal Device manufactured by 524, 542, 619, 624, 628, 642, 719, Pyromation

724, 742, and 788

3-Way Switches 405, 444, 471, 505, Three position switch manufactured by Alan 544, 571, 605, 644, 671, 705, 744, Bradley Electrical Components. The three and 771 switch positions are OFF, ON, and AUTO.

Fillers 445, 545, 645, and 745 Fillers manufactured by U.S. Bottlers, Inc., and Laub Hunt have been successfully used to fill glass and plastic containers. Fillers manufactured by F.M.C. Food Precessing Equipment, and Elmar Industries, have been successfully used to fill cans.

High/Low Probes 404, 470, 504, High/low conductivity probe manufactured 570, 604, 670, 704, and 770 by Luminite Corporation

Hot/Cold Service 417, 422, 465, Hot/cold service units manufactured by 517, 522, 565, 617, 622, 665, 717, Thermaline, Feldmeyer, A.P.V. Crepaco 722, and 765 have been successfully utilized.

F. ALTERNATE FILLER LINE PRODUCT RECOVERY.

In addition to the filler lines depicted in FIGS. 4, 5, 6, and 7, the new product recovery

method and apparatus of the present invention can also be applied to filler lines of much simpler

design. In an alternate preferred embodiment of the present invention a filler line consists of a line

tank (such as line tank 238 in FIG. 2), which functions as a holding tank for a product, connected

to a filler (such as filler 745 in FIG. 7) by a product line (such as product line 501 in FIG. 5), with

the following equipment sequentially interposed in the product line from the line tank to the filler: a line tank valve (such as valve 246), a water source (preferably a "T" valve with a water

attachment such as water 302 and "T" valve 303), a check valve with a air/gas blow attachment

(such as check valve 710 with air/gas 709 in FIG. 7), and a pump (such as pump 712 in FIG. 7).

In the first step of the product recovery process for this simplified filler line, a rinsed and

empty line tank is loaded with product. The water source is then used to rinse the product line,

check valve, pump and filler. Once the entire filler line is thoroughly rinsed, the water source is

turned off. Compressed air/gas is sent through the check valve, at a velocity and for a period of

time required to thoroughly clear the filler line of all remaining rinsing water. The rinsing water

is thus pushed into the filler, where it flows out into a drain. The line tank valve (normally closed)

is then opened, and product is allowed to flow through the product line, past the check valve, into

the pump, thus priming the pump. The pump is then activated, pumping the product forward to

the filler. Containers are sent to the filler and loaded with the product. Once the line tank is

empty, compressed air/gas is sent through the check valve, at a velocity and for a period of time

required to thoroughly clear the filler line of all remaining product. The compressed air/gas is

thus used to push the remaining product into the filler, where it flows into containers. Once

substantially all of the remaining product has been pushed into containers, the compressed air/gas

is turned off. The containers are then removed from the filler, and rinsing water is again sent into

the product line to rinse the entire filler line.

Application of the product recovery method and apparatus of the present invention to a

filler line of this simple design achieves the same results as application of the present invention to

the more complex filler lines depicted in FIGS. 4, 5, 6, and 7. The product does not come into

contact with the rinse water, because of the compressed air/gas buffer which is used to

sequentially and consecutively evacuate the rinse water and product from the filler line. Thus, substantially all of the product can be recovered while remaining substantially undiluted by the rinse water.

G. AUTOMATED PRODUCT RECOVERY.

It is contemplated that the operation of the apparatus of the present invention can be fully

automated by the use of automated device controllers, logic circuits, and suitable automatic

sensor devices. It is intended that the "filler line operator," and the "filler line operator's

discretion," in the present invention can be replaced by automated equipment, sensor devices and

logic circuits. Accordingly, the description of the apparatus and process steps of the present

invention are believed to be, and are intended to be, sufficient to permit a person skilled in the art

of designing and programming automated control systems to fully automate, without undue

experimentation, the product recovery system which is the subject of the present invention.

CONCLUSION Although the invention has been illustrated and described with respect to exemplary

embodiments thereof, it should be understood by those skilled in the art that the foregoing and

various other changes, omissions and additions may be made therein and thereto, without

departing from the spirit and scope of the present invention. Therefore, the present invention

should not be understood as limited to the specific embodiment set forth herein but to include all

possible embodiments which can be embodied within the scope encompassed and equivalents

thereof with respect to the features set out in the appended claims.

Claims

CLAIMSWhat is claimed is:

1. A method for the recovery of a product during the transfer of the product between

a tanker truck and a tank, comprising the steps of:

a. rinsing a tank and a pump connected by a product line with water;

b. evacuating the rinsing water from the product line, the pump, and the tank

by using a compressed air/gas;

c. connecting the product line to a tanker truck;

d. transferring a product from the tanker truck to the tank through the product

line with a pump, until the pump is no longer primed with the product;

e. pushing the remaining product with a compressed air/gas through the

product line, the pump, and into the tank, thereby recovering substantially all the

product remaining in the product line and the pump.

2. A method for the recovery of a product during the transfer of the product between

a holding tank and a receiving tank, comprising the steps of:

a. rinsing the receiving tank, a pump, and an interconnected product line with

rinse water;

b. evacuating the rinse water from the receiving tank, the pump, and the

product line by using compressed air/gas;

c. transferring the product from the holding tank to the receiving tank through

the product line with a pump, until the pump is no longer primed with the product; d. pushing the remaining product with compressed air/gas through the product

line, the pump, and into the receiving tank, thereby recovering substantially all the

product remaining in the product line.

3. A method for recovering a product from a filling line being used to fill containers

with the product, comprising the steps of:

a. rinsing a filling line with rinse water, said filling line comprising at least

a filler, a pump, a check valve, compressed air/gas, a water source, and a holding

tank containing the product, all interconnected by a product line;

b. evacuating the rinse water from the filling line by using the compressed

air/gas;

c. transferring the product from the holding tank to the filler, and then into

containers, through the filler line with a pump, until the pump is no longer primed

with the product;

d. pushing the remaining product with the compressed air/gas through

the filler line into the filler and then into containers, thereby recovering

substantially all the product remaining in the filler line.