US20140377418A1

US20140377418A1 - Method and Apparatus for Hub and Spoke Aseptic Processing

Info

Publication number: US20140377418A1
Application number: US13/924,327
Authority: US
Inventors: Scott Eckman; James E. Hurley
Original assignee: NOBLE HOUSE LLC
Current assignee: Sierra Enterprises LLC
Priority date: 2013-06-21
Filing date: 2013-06-21
Publication date: 2014-12-25
Also published as: WO2014205071A1

Abstract

Embodiments of hub and spoke aseptic processing system are disclosed. In one embodiment of the current invention, a spoke aseptic processing system aseptically unloads an aseptic product from an aseptic container. The aseptic product is aseptically transported in the aseptic container from a remote site. One or more pre-filtered dilution base products are sterilized. The aseptic product and the sterilized base products are sent to an aseptic pressurized blending unit to form a final product according to a predefined formula without breaking sterilization. The final product is aseptically packaged to a finish product without break the sterile chain. In other embodiments of the current invention, a monitor and tracking system is connected with the system to monitor, track and log aseptic information. The information collected can be further uploaded to a network connected central database.

Description

TECHNICAL FIELD

The disclosed embodiments relate generally to aseptic processing, and, more particularly, to methods and apparatus for hub and spoke aseptic processing.

BACKGROUND

There has been a significant market growth and associated technical development in the area of aseptic processing. Traditionally, sterility was achieved through the canning process by putting the product in a container first and heating the product and the container together. During the canning process, a lot more energy is required to heat completely the product inside the container, resulting in loss of nutrition. In contrast, during aseptic process the product is heated outside the container in a continuous, closed system, cooled and then placed into a previously sterilized container. When a food product is aseptically processed, it passes through a thin pipe where it is rapidly heated to kill pathogens before quickly cooled. The short heating time is sufficient to kill germs while minimizing the quality degradation to the food nutrition. Further, since the food is filled at ambient temperatures, containers can be made of different low-cost and light-weighted materials, such as films and paperboards.
Despite the many benefits of aseptic processing, the current aseptic processing system suffers some disadvantages. The current aseptic processing facilities aseptically process the raw materials, sterilize the product, and aseptically package the product. The aseptic plant houses the aseptic processing and aseptic packaging together or close by. The cost to establish such a full aseptic plant is quite high. The equipment cost and facility requirements for a full aseptic processing establishment require a large amount of initial investment. Such burden hinders further growth of aseptic processing and limits the flexibility of aseptic processing.
The present invention provides a hub-and-spoke system that significantly reduces the cost of establishing an innovative spoke aseptic processing facility. An aseptic packaging spoke system is provided such that aseptic products can be transported from a remote aseptic hub facility and packaged to final products without breaking the sterility chain, which starts from the beginning of the aseptic processing to the end of aseptic packaging. The spoke aseptic processing system is metered and tracked by an aseptic information system. The aseptic information system can also be connected with a centralized information system.

SUMMARY

Embodiments of hub and spoke aseptic processing system are disclosed. In one embodiment of the current invention, a spoke aseptic processing system aseptically unloads an aseptic product from an aseptic container. The aseptic product is aseptically transported in the aseptic container from a remote site. One or more pre-filtered dilution base products are sterilized. The aseptic product and the sterilized base products are sent to an aseptic pressurized blending unit to form a final product according to a predefined formula without breaking sterilization. The final product is aseptically packaged to a finish product without break the sterile chain.
In another embodiment of the current invention, aseptic flavor doses are aseptically added to the final product without breaking sterilization. In another embodiment of the current invention, an aseptic balance tank is used to receive the final product aseptically from the blending unit before sending the final product to the filling unit. In one other embodiment of the current invention, a backup sterilization system is used to re-sterilize the aseptic product if the system detects that the sterilization is compromised. In one other embodiment of the current invention, a second aseptic pressurized blending tank is provided such that the aseptic filling and packaging unit receives continuous final product from one of the blending unit. When one of the aseptic blending unit unloads the entire final product, it restarts to receive ingredients to produce new batches of final product. At the same time, the other blending unit would have finished properly blending all the ingredients and starts to feed the filling unit or the balance unit so that the system does not need to wait for the other blending unit to finish blending new final products.
In other embodiments of the current invention, a monitor and tracking system is connected with the system to monitor, track and log aseptic information. A meter and control system is connected with aseptic spoke system to control and measure the flow rate of all the ingredients. In one embodiment of the current invention, the information collected from the monitor and tracking system can be further uploaded to a network connected central database. The monitor and tracking system and the meter and control system can be further connected via a network to a central aseptic center to receive information from other sites and to update information to the central aseptic database.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary diagram of a hub and spoke aseptic processing system.

FIG. 2 shows an exemplary block diagram of an aseptic spoke system.

FIG. 3 is an exemplary flow chart of an aseptic spoke system in accordance with embodiments of the current invention.

FIG. 4 is an exemplary flow chart of a spoke aseptic processing procedures in accordance with embodiments of the current invention.

DETAILED DESCRIPTION

Reference will now be made in detail to some embodiments of the invention, examples of which are illustrated in the accompanying drawings.
FIG. 1 is an exemplary diagram of a hub and spoke aseptic processing system 100. Hub and spoke system 100 comprises two hub facilities Hub 101 and Hub 102, and a plurality of spoke facilities 111-115 and 121-125. Hub 101 and Hub 102 are two aseptic hub facilities. The hub facilities process the raw materials and sterilize the products. Hub 101 and Hub 102 can have packaging equipments and produces final products. It can also produce aseptically processed products stores in large aseptic containers. These aseptic containers can have either concentrated juices or single strength juices that are commercially sterile. Hub 101 and Hub 102 can provide these aseptic products to multiple spoke facilities for dilution and packaging to final products.
As shown in FIG. 1, spoke facilities 111, 112, 113, 114 and 115 receive aseptic products from Hub 101. Spoke facilities 115, 121, 122, 123, 124 and 125 receive aseptic products from Hub 102. Further shown in FIG. 1, one spoke facility can receive aseptic products from multiple hub facilities. Spoke facility 115 receives aseptic products from both Hub 101 and Hub 102. The location of hubs and spokes can be strategically located to serve different markets. As needs arise, new spoke facilities can be easily added to serve additional market need because the innovative aseptic spoke system is easy to setup and costs much less than the traditional full aseptic plant.
FIG. 1 further shows a system level overview of an exemplary hub system 130. Hub system 130 receives raw materials 131 and processes these raw materials according to predefined process. The processed product of raw materials 131 was sent to aseptic processing 132 where the product is aseptically processed. The aseptic processing 132 includes passing the product in a continuous, closed system where it is quickly heated and cooled. The aseptically processed product is then sent to aseptic container 133. The aseptic containers can be any type of aseptic containers, such as an aseptic tank, an aseptic drum or an aseptic tote. The aseptic products can be either concentrated juices or single strength juices that are commercially sterile. For example, aseptic container 133 can be five-thousand-gallon aseptic tanker and an unloading valve. Aseptic container 133 can be a fifty-five-gallon drum with an aseptic bag and an aseptic unloading valve inside. Aseptic container 133 can be an aseptic tote with an aseptic bag and an aseptic unloading valve for volumes from two hundred fifty liters to one thousand liters. Any type of aseptic container 133 can be shipped by available transportation means such as trucks, trains or ships. The aseptic product in aseptic container 133 can be transported aseptically to remote places, including across continents and oceans, without breaking the sterility of the product in ambient or controlled conditions. Transportation means 134 takes aseptic container 133 and transports the aseptic product from the hub to other spoke facilities.
Furthermore, FIG. 1 shows a system level overview of an exemplary spoke system 140. Transportation 141 aseptically transports aseptic product from remote facility without breaking the sterility chain. When spoke system 140 receives aseptic containers, an aseptic hose is connected to the aseptic valve of the container (not shown). The aseptic hose is first sterilized before connecting to the aseptic valve and the spoke system. In one novel aspect, the aseptic hose is specially designed so that one end of the opening that connects to the container is of standard size while the other end that connects to the spoke system 140 is of a proprietary size. Therefore, the special designed aseptic hose is required to load the aseptic product from an aseptic container to spoke system 140. Once the aseptic hose is sterilized and the valve attached to the container is sterilized, the valve can be opened to send either the concentrated juices or the single strength juices to spoke system 140 without breaking sterility.
Aseptic product 142 unloaded from transportation 141 can be held in an aseptic holding tank or directly fed into aseptic blend tank 145. Spoke system 140 has two additional components to sterilize pre-filtered water and liquid sweetener. Water sterilizer 143 sterilizes pre-filtered water and sends the sterilized water to aseptic blend tank 145. Sweetener sterilizer 144 sterilizes pre-filtered liquid sweetener and sends the sterilized liquid sweetener to aseptic blend tank 145. In one novel aspect, aseptic product 142, water sterilizer 143, and sweetener sterilizer 144 are all metered and controlled by a central monitor and track system 151. The ingredients, including the aseptic product, the sterilized water and the sterilized sweetener are metered by the individual volume equipments of the finished product according to a predefined formula.
Aseptic blend tank 145 is an aseptic pressurized blending tank to mix properly the ingredients into the final dilution without breaking sterility. The properly blended final product is sent to aseptic balance tank 146 where the final product is being held before sending to the filling equipment. In one novel aspect of the current invention, there are two aseptic pressurized blending units such that when one blending unit finishes blending the product and sending the final product to the aseptic balance tank, spoke system 140 meters the ingredients into the second aseptic blending unit. With a second blending unit, aseptic balance tank 146 can be fed by two blending units alternatively without waiting for blending process. When the first aseptic blending unit empties its final product, the second aseptic blending unit would have finished blending its final product such that it can feed aseptic balance tank 146 while first aseptic blending unit starts to take in ingredients or blending the ingredients. Alternatively, the second aseptic blending unit upon finishing blending can send the final product to the first aseptic blending unit, which sends the finished product to aseptic balance tank 146.
Aseptic balance tank 146 sends the final product to aseptic filler 147 to packaging the final product to finished products. Aseptic filler 147 can fill the final product to Bric-Pak (juice boxes), bags, bottles or any other aseptic packages without breaking sterility.
In one novel aspect, spoke system 140 also includes backup sterilizer 148. Backup sterilizer 148 can re-sterilize aseptic product 142 when spoke system 140 detects that sterility of aseptic product 142 might have been compromised. Upon detections of possible compromise of sterility of aseptic product 142, spoke system 142, instead of sending it directly to aseptic blend tank 145, sends aseptic product 142 to backup sterilizer 148. Backup sterilizer 148 takes aseptic product 142, re-sterilizes it and then sends the re-sterilized aseptic product to aseptic blend tank 145. For example, spoke system 140 has flow meters in the pipes that monitor flow rate and pressure of the system. If at any time, the flow meters detect that the flow rate or pressure from the aseptic container or from the unloading tank drops below a predefined threshold level, spoke system 140 will close all valves. The aseptic product from the container or the unloading tank will be removed and sent to backup sterilizer 148 to insure sterility. Other information may also indicate compromise of sterility of the aseptic product.
All the ingredients and equipments, including pumps, valves and tanks in spoke system 140 are metered and controlled by meter and control system 152. Meter and control system 152 includes flow meters, valve and pump controllers, and ingredient formula units. The flow meters measure flow rate and pressure of each components of spoke system 140. The ingredient formula units control the components in the spoke system according to a predefined formula or specification. The predefined formula or specifications can be dynamically updated through meter and control system 152. The equipment components and ingredients are also further monitored and tracked by monitor and track system 151. Monitor and track system 151 collects, monitors and tracks aseptic information about spoke system 140. Such aseptic information includes an origination hub information, destination spoke site information, quantity information of the aseptic product, transportation company and transportation route information, a bill of laden, a product number from the remote site, a certificate of analysis from the remote site, a product specification, product batch information from the remote site, and formula information of the final product. Monitor and track system 151 can further take aseptic information from meter and control system 152, such as flow rate, pressure and other available information collected. The aseptic information can be updated manually or automatically. Monitor and track system 151 can further dynamically adding, deleting or updating entries of aseptic information being tracked.
In one novel aspect of the current invention, as further shown in FIG. 1, hub system 130 and spoke system 140 can be connected with network 150. Network 150 can connect with multiple hubs and spokes and maintain a central database that tracks and logs activities in the whole system. Hub system 130 and spoke system 140 can upload their collected aseptic information to the central database through network 150. Hub system 130 and spoke system 140 can also receive information from the central database through network 150.
FIG. 2 shows an exemplary block diagram of an aseptic spoke system 200. Spoke system 200 receives aseptically transported aseptic container in transportation unit 201, which transports aseptic products from a remote site. The aseptic containers in transportation unit 201 are unloaded to aseptic transfer platform 202. In one embodiment of the current invention, aseptic transfer platform 202 has a weight scale (not shown) where the unloaded aseptic totes or aseptic drums can be placed on. The weight scale of aseptic transfer platform 202 provides the exact weight information of the product volumes to the system. The information can be passed to the aseptic information database of aseptic spoke system 200. When aseptic spoke system 200 receives aseptic products from an aseptic tanker, the received aseptic products can be unloaded to aseptic holding tank 203 through valve 265 aseptic hose 210. In one embodiment of the current invention, aseptic hose 210 is sized to connect to the commercially available aseptic tanker, and differently sized at another end to be the only way to connect to aseptic spoke system 200. Holding tank 203 holds unloaded aseptic product and sending the aseptic product to be further processed in aseptic spoke system 200. Aseptic spoke system 200 can have multiple holding tanks. In one embodiment of the current invention, aseptic transfer platform 202 connects to valve 266 through aseptic pump 231. Aseptic transfer platform 202 can send the aseptic product to aseptic holding tank 203 through valve 266, which is connected with valve 265. Aseptic loading tank can also directly send the aseptic product to a blending tank through valve 250, which is connected to valve 266. Aseptic holding tank 203 connects to valve 250 through pump 232. Valve 250 connects to valve 251. Through valve 251, the aseptic products in either aseptic transfer platform 202 or aseptic holding tank 203 can either be sent to a blending unit through aseptic pump 245 or be sent to backup sterilization system 206 when detecting sterility has been compromised. In one embodiment of the current invention, aseptic containers, such as aseptic totes or aseptic drums directly connects to aseptic pump 232 through aseptic hose 210. In one embodiment of the current invention, the aseptic hose is sized to connect to the commercially available totes and drums at one end, and differently sized at another end such that the aseptic hose is required to connect to aseptic spoke system 200.
The aseptic product transported aseptically by transportation 201 from a remote site is received at aseptic spoke system 200. The aseptic product in different aseptic containers can be unloaded to aseptic transfer platform 202, which is connected to one or more blending units, or to aseptic holding tank 203, which is also connected to the one or more blending units.
Central control system 280 has two subsystems: monitor and track subsystem 281 and meter and control subsystem 282. Monitor and track subsystem 281 and meter and control subsystem 282 can reside in one single box, or can reside in different computers while being connected via dedicated physical links or through a network. Monitor and track subsystem 281 monitors and tracks aseptic information of aseptic spoke system 200. Meter and control system 282 measures and controls the flow of aseptic spoke system 200.
FIG. 2 also shows backup sterilization system 206 that is connected to aseptic transfer platform 202 and aseptic holding tank 203 through valve 251. Upon detecting sterilization is compromised, valve 251 is set to send the aseptic products from either aseptic transfer platform 202 or aseptic holding tank 203 to aseptic pump 233, which sends the aseptic products to backup sterilization system 206. Backup sterilization system 206 re-sterilizes the aseptic product and can send the output to a blending unit through valve 252 through aseptic pump 234.
Other components of aseptic spoke system 200 include sterilization system for one or more pre-filtered products, such as water and liquid sweeteners. Aseptic pump 235 aseptic pumps pre-filter water to water-sterilization system 204. The sterilized water is pumped by aseptic pump 236 to be sent to a blending unit via valve 263. Liquid sweeteners unloaded from transportation 209 through aseptic pump 237. The pre-filtered liquid sweeteners were pumped into sweetener sterilization system 205 through aseptic pump 237. In one embodiment of the current invention, the sterilized liquid sweeteners was pumped to aseptic buffer 207 through aseptic pump 238. The sterilized liquid sweeteners in aseptic buffer 207 can be sent to a blending unit through valve 263 via aseptic pump 239. In one embodiment of the current invention, water sterilization system 204 uses Reverse Osmosis (RO) and Ultra Violet (UV) technologies. Liquid sweeteners are heat process to achieve sterility in Liquid sweetener sterilization system 205.
In one embodiment of the current invention, aseptic flavor doses are added to the aseptic final product via aseptic dose flavor system 208. Aseptic doses can be sent to an aseptic blending unit through valve 264 via aseptic pump 240.
All the ingredients are controlled by central control system 280 to be sent to an aseptic blending unit according to a predefined formula. The aseptic product unloaded from either aseptic transfer platform 202 or aseptic holding tank 203 is pumped to an aseptic blending unit via valve 252. Valve 252 also connects with the output of backup sterilization system 206 when detecting compromised sterilization. The sterilized pre-filtered base products, such as water and liquid sweeteners together with aseptic flavor doses are sent to a blending unit via valve 255. Valve 255 connects to valve 264, which also connects to aseptic pump 240 that pumps aseptic flavor doses and valve 263. Valve 263 connects to aseptic pumps 236 and 239, which pumps sterilized water and sterilized liquid sweeteners, respectively. The aseptic blending unit receives the right amount of each ingredient and properly blends them without breaking the sterility chain.
In one embodiment of the current invention, aseptic spoke system 200 includes two aseptic blending units: first aseptic blending unit 211 and second aseptic blending unit 212. The outputs of first aseptic blending unit 211 and second aseptic blending unit 212 both connects to valve 260, which connects to aseptic pump 244 that pumps the final products to aseptic balance tank 213. The advantage of having two aseptic blending units is to continuously feeding aseptic balance tank 213 and aseptic filler 214 such that the packaging of the finishing product operates continuously without stopping to wait for one aseptic blending unit while blending. In one embodiment of the current invention, second aseptic blending unit 212 can also send its final product to first aseptic blending unit 211 via valves 259, 256 and 257.
As exemplary illustrated in FIG. 2, first aseptic blending unit 211 receives all its ingredients through valve 257. Valve 257 receives aseptic product by connecting to valve 258, which connects to valve 253. Valve 253, connecting to valve 252, receives aseptic product either directly from aseptic transfer platform 202 or aseptic holding tank 203, or from outputs of backup sterilization system 206. Valve 257 also receives sterilized base products and aseptic flavor doses by connecting to valve 256, which connects to valve 255. Valve 255 connects to valve 264, which in one end connects to receive aseptic flavor doses, and in the other end connects to valve 263 to receive sterilized dilution base products. Through valve 257, first aseptic blending unit 211 receives all ingredients according to a predefined formula and properly blends them without breaking sterility chain. Once the ingredients are properly blended, aseptic pump 242 sends the final product to aseptic balance tank 213 through valves 260 and 261.
Similarly, second aseptic blending unit 212 receives all its ingredients through valve 254. Valve 254 receives aseptic product by connecting to valve 253. Valve 253, connecting to valve 252, receives aseptic product either directly from aseptic transfer platform 202 or aseptic holding tank 203, or from outputs of backup sterilization system 206. Valve 254 also receives sterilized base products and aseptic flavor doses by connecting to valve 255. Valve 255 connects to valve 264, which in one end connects to receive aseptic flavor doses, and in the other end connects to valve 263 to receive sterilized dilution base products. Through valve 254, second aseptic blending unit 211 receives all ingredients according to a predefined formula and properly blends them without breaking sterility chain. Once all ingredients are blended, aseptic pump 241 sends the final product to aseptic balance tank 213 through valves 259, 260 and 261.
In one embodiment of the current invention, when a single strength aseptic product is received, the single strength aseptic product is sent directly to aseptic balance tank 213 without going an aseptic blending unit. When a single strength aseptic product is received, valve 253 sends the aseptic product to valve 258, which opens to valve 261 directly. Valve 261 opens to send the single strength aseptic product to aseptic balance tank 213 without going through an aseptic blending unit.
Aseptic balance tank 213 receives properly blended final product from an aseptic blending unit or single strength aseptic product through aseptic pump 244. Valve 262, connecting with aseptic balance tank 213 meters and controls the final product. Aseptic pump 243, connecting to aseptic filler 214, pumps final products from aseptic balance tank 213 to aseptic filler 214. Aseptic filler 214 fills the aseptic final product into aseptic packages without breaking the sterility chain.
In one embodiment of the current invention, flow meters measure and control the amount of products sending through the system. The flow rate and amount are also recorded within the network for documentation and validation. FIG. 2 shows exemplary flow meters. Flow meter 272 measures and controls the aseptic product going into aseptic holding tank 203. Flow meter 273 measures and controls the aseptic product going out of aseptic transfer platform 202. Flow meter 274 measures and controls the aseptic product going out of aseptic holding tank 203. Flow meter 275 measures and controls the aseptic product going into either of the aseptic blending tanks. Flow meter 276 and 277 measures and controls the liquid sweetener going in and out of liquid sweetener sterilization system 205, respectively. Flow meter 278 measures and controls water going out of water sterilization system 204. Flow meter 279 measures and controls aseptic flavor doses going into either of the aseptic blending tank. Flow meter 280 measures and controls the aseptic product going out of backup sterilization system 206. Flow meters 281 and 282 measure and control the aseptic final product going out of first aseptic blending unit 211 and second aseptic blending unit 212, respectively. Flow meters 283 and 284 measures and controls the aseptic final product going into aseptic balance tank 213 and aseptic filler 214, respectively.
All aseptic valves, aseptic pumps, aseptic flow meters are connected to central control system 280 and are computer controlled. Central control system 280 controls the aseptic valves, aseptic pumps and aseptic flow meters according to a predefined formula. The predefined formula can be dynamically updated. In one embodiment of the current invention, central control system 280 is connected to network 270, which can be connected further to other information or control systems of different sites.
FIG. 3 is an exemplary flow chart of an aseptic spoke system in accordance with embodiments of the current invention. Step 301 determines which blending tank is available. Step 302 receives aseptic products. The aseptic product is received from an aseptic container, which is transported from a remote site, such as a remote aseptic hub plant. Step 303 logs the information of the received aseptic product. Step 304 determines whether sterilization is compromised. If step 304 determines that sterilization is compromised, the process moves to step 311, which updates aseptic log information and moves to step 312. Step 312 sends the possibly compromised aseptic product to the backup sterilizer to re-sterilize the aseptic product. After the product is re-sterilized in the backup sterilization system, the product is sent to the pre-determined available aseptic pressurized blending tank. If step 304 determines that the sterility of the aseptic product is not compromised, it moves to step 322, which sends the product to the pre-determined available aseptic pressurized blending tank. Step 313 sterilizes pre-filter water through the water sterilization system. The process then moves to step 323, which sends the sterilized water to the pre-determined available aseptic pressurized blending tank. Step 314 sterilizes pre-filter liquid sweeteners through the liquid sweetener sterilization system. The process then moves to step 324, which sends the sterilized liquid sweetener to the pre-determined available aseptic pressurized blending tank. Step 305 determines whether flavors are needed for the final product according to a predefined formula. If step 305 determines that one or more flavors are needed, it moves to step 325. Step 325 sends aseptic flavor doses to the pre-determined available aseptic pressurized blending tank. Step 326 determines whether a predefined ingredient volume has reached for each ingredient. If step 326 determines that the predefined ingredient volume is reached, the process moves to 331, which blends all received ingredients in the aseptic pressurized blending unit.
Once the ingredients are aseptically blended, the process moves to step 332. Step 332 sends the properly and aseptically blended final product to the balance unit. Step 333 sends the final product in the balance tank to the filling unit. Step 334 takes final product from the filling unit and aseptically packages it to the finish product without breaking the sterility chain. After sending the final product to the balance unit, the system moves to step 335 to determine whether the blending tank is empty by sending the entire final product to the balance unit. If step 335 determines that the blending tank is empty, it moves to step 336. Step 336 marks the blending tank as available. The blending tank is now ready to take in new ingredients.
FIG. 4 is an exemplary flow chart of a spoke aseptic processing procedures in accordance with embodiments of the current invention. Step 401 aseptically unloads an aseptic product from an aseptic container, wherein the aseptic product is aseptically transported in the aseptic container from a remote site. Step 402 sterilizes one or more pre-filtered dilution base products. Step 403 blends the aseptic product with one or more sterilized dilution base products to form a final product according to a predefined formula without breaking sterilization. Step 404 packages the final product aseptically without breaking sterile chain.
Although the present invention has been described in connection with certain specific embodiments for instructional purposes, the present invention is not limited thereto. Accordingly, various modifications, adaptations, and combinations of various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the claims.

Claims

What is claimed is:

1. A method, comprising:

aseptically unloading an aseptic product from an aseptic container, wherein the aseptic product is aseptically transported in the aseptic container from a remote site;

sterilizing one or more pre-filtered dilution base products;

blending the aseptic product with one or more sterilized dilution base products to form a final product according to a formula without breaking sterilization; and

packaging the final product aseptically without breaking a sterile chain.

2. The method of claim 1, wherein the dilution base products include water and liquid sweeteners.

3. The method of claim 1, wherein the unloading involves connecting the aseptic container with a sterilized unloading hose, wherein the sterilized unloading hose comprises a first opening end connecting to the aseptic container and a second opening end connecting to a valve, and wherein the first opening end and the second opening end have different size.

4. The method of claim 1, wherein aseptically unloading the aseptic product comprises connecting an aseptic valve to the aseptic container, and wherein the aseptic valve is either a one-time aseptic valve or a valve being externally sterilized before connecting to the aseptic container.

5. The method of claim 1, further comprising:

adding aseptic flavoring doses during the blending process.

6. The method of claim 1, further comprising:

checking the aseptic product to determine whether the sterilization of the compound aseptic is comprised; and

unloading the aseptic product to a backup sterilizing unit and re-sterilizing the aseptic product if the sterilization of the aseptic product is compromised.

7. The method of claim 1, further comprising:

monitoring and tracking one or more aseptic information, wherein the aseptic information comprises: origination hub information, destination spoke site information, quantity information of the aseptic product, transportation company and transportation route information, a bill of laden, a product number from the remote site, a certificate of analysis from the remote site, a product specification, product batch information from the remote site, and formula information of the final product.

8. The method of claim 7, further comprising:

sending the tracking information to a preconfigured aseptic information center.

9. The method of claim 1, further comprising:

automatically metering and controlling a filling volume requirement of one or more of ingredients according to the formula, wherein the ingredients comprises: the aseptic product, the dilution base products and flavoring dosing products.

10. The method of claim 1, wherein the formula can be dynamically updated.

11. An apparatus, comprising:

an aseptic unloading hose, which connects to an aseptic container and a first valve, wherein the aseptic container contains an aseptic product that is aseptically transported from a remote site,

one or more sterilization units, which sterilize one or more pre-filtered dilution base products;

an aseptic pressurized blending unit, which blends the aseptic product with one or more sterilized dilution base products to form a final product according to a formula without breaking sterilization; and

an aseptic filling unit, which aseptically fills a plurality of aseptic packages with the final product without breaking a sterile chain.

12. The apparatus of claim 11, wherein the dilution base products include water and liquid sweeteners.

13. The apparatus of claim 11, wherein the aseptic unloading hose has a first opening end and a second opening end, wherein the first opening end and the second opening end have different size, and wherein the second opening is sized to connect to the first valve.

14. The apparatus of claim 11, further comprising:

a second aseptic valve, which connects to the aseptic pressurized blending unit and an aseptic flavoring dose source, wherein one or more aseptic flavoring doses are added to the aseptic pressurized blending unit.

15. The apparatus of claim 11, further comprising:

a backup sterilization unit, which sterilizes the compound aseptic product when detecting sterilization of the aseptic product is compromised.

16. The apparatus of claim 11, further comprising:

an unloading platform upon which the aseptic containers are placed and weighed before unloading the aseptic product.

17. The apparatus of claim 11, further comprising:

an aseptic pressurized balance unit, which connects to the aseptic pressurized blending unit and the aseptic filling unit, and wherein the final product is first received at the aseptic pressurized balance unit before being sent to the aseptic filling unit.

18. The apparatus of claim 11, further comprising:

an aseptic holding tank that connects to the aseptic container to unload and to hold the aseptic product before sending the aseptic product for further processing.

19. The apparatus of claim 11, further comprising:

a second blending unit that aseptically blends aseptic product with one or more sterilized dilution base products to form the final product according to the formula without breaking sterilization, wherein the second blending unit together with the blending unit provide continuous final product flow to the aseptic filling unit.

20. The apparatus of claim 11, further comprising:

a monitor and a plurality of tracking units, which monitor and track one or more aseptic information, wherein the aseptic information comprises: origination hub information, a destination spoke site information, quantity information of the aseptic product, transportation company and transportation route information, a bill of laden, a product number from the remote site, a certificate of analysis from the remote site, a product specification, product batch information from the remote site, and formula information of the final product.

21. The apparatus of claim 11, further comprising:

a communication unit, which sends the aseptic information to a preconfigured aseptic information center.

22. The apparatus of claim 11, further comprising:

a plurality of automatic meter and control units, which automatically meter and control a filling volume requirement of one or more of ingredients according to the formula, wherein the ingredients comprises: the compound aseptic product, the dilution base products and flavoring dosing products.

23. The apparatus of claim 11, wherein the formula can be dynamically changed.