WO2006010997A1

WO2006010997A1 - An apparatus and method of ultrasonic cleaning

Info

Publication number: WO2006010997A1
Application number: PCT/IB2004/003140
Authority: WO
Inventors: Darren Miles Bates; Andrew Sin Ju Yap; Arthur Richard Mcloughlin; William Albert Wright; David Leigh Wake
Original assignee: Darren Miles Bates; Andrew Sin Ju Yap; Arthur Richard Mcloughlin; William Albert Wright; David Leigh Wake
Priority date: 2004-07-16
Filing date: 2004-07-16
Publication date: 2006-02-02

Abstract

An apparatus for and method of cleaning the interior surfaces of barrels and destroying microorganisms is disclosed. In one embodiment, an ultrasonic apparatus includes a sonotrode placed within a bunghole of a barrel. An ultrasonic generator is connected to the sonotrode. The ultrasonic apparatus also includes an ultrasonic transducer connected to the ultrasonic generator and associated with the sonotrode.

Description

AN APPARATUS AND METHOD OF ULTRASONIC CLEANING

FIELD OF THE INVENTION

[001] The present invention relates generally to ultrasonics and, more particularly, to an apparatus and method of ultrasonic cleaning.

BACKGROUND OF THE INVENTION

[002] The recycling of wine barrels is common practice within the wine industry. Reusing barrels is one of the ways that wineries can reduce their overheads. This is especially true in large wineries where multiple hundreds of barrels are in circulation at any one time. Barrels have a limited life and are only able to be cleaned a certain number of times. To extend the life of a barrel, it is first used for white wines, cleaned and then used for red wines. The time that the wine spends in a particular barrel depends on the type and quality of the wine that is being produced. [003] The wood of a new barrel imparts the most flavor into the wine, with the effect being diminished with each re-use of the barrel. Therefore since new barrels are expensive their initial use is normally reserved for premium wines. The third use of a barrel usually doesn't add much flavor to the wine. For this reason many producers manage their barrels carefully, ageing their wine in a mix of new and used barrels to avoid over-oaking the wine. Care however must be taken in the use of older barrels, since the interior can harbor bacteria and yeasts that might contaminate the wine that is to be placed in the cleaned barrel. Such contamination costs the wine industry vast amounts each year in spoilt wine. Furthermore, the winemaker will not know whether a wine has been spoilt until it has spent some time in the barrel. [004] In order to overcome this problem, the inner surface of the wine barrel is often shaved to remove wine residues. Various apparatuses including cutting routers, planes and rotating wire brushes have been used to remove a small amount of wood off the inner surface of the barrel's staves. The process involves either the dismantling of the barrel or the removal of one end of the barrel. The wood of the interior of the barrel is then shaved to remove residues. Shaving the wood reduces the chance of contaminating the wine that is to be placed in the barrel at a latter time. The method however is not time effective since the barrel must be moved to a location where it can be shaved. Furthermore the inner surface of the barrel must be re-toasted. [005] Other methods used for cleaning and/or decontaminating a barrel involve the use of high- pressure hot or cold water or steam to clean the interior surface of the barrel. A high-pressure water or steam lance is inserted through the bunghole and is manually manipulated or rotated to spray jets of water or steam over the internal surface of the barrel. This loosens the wine residue, tartrates and the like which can then be removed. The detritus can then be drained by the use of a pump or by inverting the barrel.

[006] An alternate method that is used involves inverting the barrel over a cleaning nozzle that sprays high-pressure hot or cold water or steam over the interior surface of the barrel. The advantage of using steam or high-pressure hot water to clean the residue from the interior surface is that it also disinfects the surface. However, both methods of using steam or water are limited because they require the application of the steam or water to occur directly on the inner surface of the barrel. This poses problems especially around the bunghole, as it is difficult to rotate the nozzle to a position where the surface is directly contacted by the steam or water. Furthermore these methods often require a large amount of water and power as the water needs to be heated.

SUMMARY OF THE INVENTION

[007] An apparatus for and method of cleaning the interior surfaces of barrels and destroying microorganisms is disclosed. In one embodiment, an ultrasonic apparatus includes a sonotrode placed within a bunghole of a barrel. An ultrasonic generator is connected to the sonotrode. The ultrasonic apparatus also includes an ultrasonic transducer connected to the ultrasonic generator and associated with the sonotrode.

BRIEF DESCRIPTION OF THE DRAWINGS

[008] The accompanying drawings, which are included as part of the present specification, illustrate the presently preferred embodiment of the present invention and together with the general description given above and the detailed description of the preferred embodiment given below serve to explain and teach the principles of the present invention.

Figure 1 illustrates a perspective view of a wine barrel with an exemplary ultrasonic sonotrode that is inserted through the bunghole of the wine barrel and is able to rotate, according to one embodiment of the present invention;

Figure 2 illustrates a side cut away view of a wine barrel completely or partially filled with water, and has an exemplary ultrasonic sonotrode that is able to rotate, according to one embodiment of the present invention;

Figure 3 illustrates a side cut away view of a wine barrel that is completely or partially filled with water and has an exemplary ultrasonic processor with a linear sonotrode, according to one embodiment of the present invention;

Figure 4 illustrates a side cut away view of a wine barrel that is completely or partially filled with water and has an exemplary ultrasonic processor with multiple curve linear sonotrodes, according to one embodiment of the present invention;

Figure 5 illustrates a side cut away view of a wine barrel that is completely or partially filled with water and has an exemplary ultrasonic processor with a linear sonotrode which has nodules along its length, according to one embodiment of the present invention;

Figure 6 illustrates a side cut away view of a wine barrel that is completely or partially filled with water and has an exemplary ultrasonic processor with attached sensor which can move semi independently from the sonotrode, according to one embodiment of the present invention;

Figure 7 illustrates a side cut away view of a wine barrel that has an exemplary ultrasonic processor with a series of sensors located along the sonotrode of the processor, according to one embodiment of the present invention; Figure 8 illustrates a side cut away view of a wine barrel that has an exemplary sonotrode positioned in water contained within a funnel, according to one embodiment of the present invention; and

Figure 9 illustrates a flow diagram of an exemplary method of ultrasonic cleaning, according to one embodiment of the present invention.

DETAILED DESCRIPTION [009] An apparatus for and method of cleaning the interior surfaces of barrels and destroying microorganisms is disclosed. In one embodiment, an ultrasonic apparatus includes a sonotrode placed within a bunghole of a barrel. An ultrasonic generator is connected to the sonotrode. The ultrasonic apparatus also includes an ultrasonic transducer connected to the ultrasonic generator and associated with the sonotrode. [0010] The following detailed description refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. For purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.

[0011] The practice of recycling wine barrels by way of cleaning is used extensively within the wine industry. However bacterial and yeast contaminations resulting from incomplete cleaning costs the wine industry vast amounts each year in spoilt wine. The difficulty with wine and liquor barrels is that the opening of the container is restricted. This poses significant problems when such a container is cleaned. Previously the barrels were dismantled and shaved, however, recently high-pressure water or steam has been used to clean such containers. This, however, presents other problems especially in drier areas where winemakers have limited water available. The present embodiments use ultrasonics to clean wine barrels and like containers with restricted access.

[0012] The present apparatus and method for cleaning wine barrels using ultrasonics overcome at least some of the aforementioned problems and provides the wine industry with a useful alternative. According to one embodiment of the present apparatus and method of ultrasonic cleaning, the ultrasonic energy emitting shaft, hereinafter referred to as the sonotrode, can be introduced into the barrel through the bunghole, thereby avoiding the need to dismantle the wine barrel, hi another embodiment of the present invention, an apparatus and method of ultrasonic cleaning allows the cleaning of the barrel in situ, without the barrel having to be moved off site.

[0013] In yet a further embodiment, an apparatus and method of ultrasonic cleaning introduces the sonotrode into a funnel of water exterior to the barrel. The funnel is connected to the bunghole in a watertight manner and is intimately connected to the water inside the barrel so as to form a continuous body of water. [0014] Generally, the wine barrels are cleaned by the use of ultrasonics. This cleaning method works by the action of microscopic cavities collapsing and releasing shock waves. The microscopic cavities are formed by sending sound at high frequencies into a body of liquid within the barrel. [0015] As illustrated in Figures 1-8, the sonotrode 12 of an ultrasonic processor 10 is inserted into the bunghole 20 of a wine barrel 22. The reader should however understand that the present invention is not limited to wine barrels and can be used to clean any container with limited access such as liquor barrels or casks. Additionally, references to the use of water as the liquid within the barrel are used for illustrative purposes. However, other similar liquids and fluids (including gasses) may be used in alternate embodiments. [0016] Figure 1 illustrates a perspective view of a wine barrel 22 with an exemplary ultrasonic sonotrode 12 that is inserted through the bunghole 20 of the wine barrel 22 and is able to rotate along path 28, according to one embodiment of the present invention. Figure 1 shows an ultrasonic processor 10 including a sonotrode 12, a handle 14, an intermediate flange 16, and a generator 18. At least one ultrasonic transducer (not shown) is associated with the sonotrode 12. The total diameter of the sonotrode is less than the diameter of the bunghole 20 of a wine barrel 22 comprising a series of staves 24 and metal rings 26. The sonotrode 12 may be fixed in a single position or able to pivot 28 as illustrated in Figure 1. The sonotrode 12 is preferably made from titanium however the reader should understand that the invention is not limited to an ultrasonic processor 10 with titanium sonotrode 12.

[0017] As illustrated in Figure 1 an intermediate flange 16 holds the ultrasonic processor 10 in place once the sonotrode 12 has been inserted through the bunghole 20. The intermediate flange 16 does not have to produce a perfect seal as the cleaning is only a short-term process and little water will be lost. However, the flange 16 prevents the ultrasonic processor 10 from being dislodged from the bunghole 20 when the barrel 22 is rotated or moved. The average diameter of a bunghole of a standard wine barrel is between 49-50 mm at the outside surface of the barrel and 47-48 mm at the interior surface. Therefore the sonotrode 12 of the ultrasonic processor 10 is less than the smallest diameter of the bunghole 20, according to one embodiment. In alternate embodiments, the sonotrode 12 maybe tapered. [0018] The generator 18 produces an ultrasonic signal that is emitted by the transducer associated with the sonotrode 12, inside the barrel 22. The ultrasonic cleaning method works by the action of microscopic cavities collapsing and releasing shock waves. The microscopic cavities are formed by sending sound at high frequencies into a body of liquid that is in contact with the surface to be cleaned. In the present embodiment, the microscopic cavities form on the interior surface of the wooden staves 24 of the wine barrel 22. The shock waves produced by the collapse of the cavities loosen the wine residue, tartrates, and the like. This detritus can then be drained by the use of a pump or by inverting the barrel and allowing the detritus to drain out through the bunghole 20.

[0019] To avoid the creation of a standing wave, the water within the wine barrel 22 may be agitated. This can be accomplished by either agitating the water using a pump (not shown) or by allowing the sonotrode 12 of the ultrasonic processor 10 to rotate or pivot through arc 28. [0020] Figure 2 illustrates a side cut away view of a wine barrel 22 completely or partially filled with water, and has an exemplary ultrasonic sonotrode 12 that is able to rotate along arc 28, according to one embodiment of the present invention. As illustrated in Figure 2, the sonotrode 12 of the ultrasonic processor 10 can pivot around arc 28 around axis 30. The axis 30 is located at the point where the sonotrode 12 enters the wine barrel 22 through the bunghole 20. The intermediate flange 16 is adapted to allow movement of the sonotrode 12 by applying pressure to the handle 14. As further illustrated in Figure 2, the wine barrel 22 does not need to be completely filled with liquid. In the present example the barrel 22 is only half filled 32 with liquid 34. As the reader would now appreciate reducing the amount of water used is a significant advantage especially where cleaning is performed in areas having restricted water access.

[0021] In another embodiment of the invention, a pump (not shown) can be used to recycle the water through a filter, thus limiting the amount of water required for the cleaning process. [0022] Since the wine barrel is only half filled 32 with liquid 34 the barrel 22 must be rotated on at least one axis, preferably the horizontal axis according to one embodiment, so that all surfaces of the barrel come in contact with the liquid 34 and ultrasonic cavitations. Rollers that are commonly used in the wine industry to rotate barrels 22 would be sufficient for this task. It should however be understood that the invention is not limited to half filled barrels. The barrel may be completely or partially filled with liquid that is then filtered and recycled for use in cleaning other barrels.

[0023] Figure 3 illustrates a side cut away view of a wine barrel 22 that is completely or partially filled with water and has an exemplary ultrasonic processor 10 with a linear sonotrode 12, according to one embodiment of the present invention. The sonotrode 12 may be positioned with the intermediate flange 16 where it passes through the bunghole 20 of the wine barrel 22 and where it can rotate as previously described.

[0024] Figure 4 illustrates a side cut away view of a wine barrel 22 that is completely or partially filled with water and has an exemplary ultrasonic processor 10 with multiple curvilinear sonotrodes 12a and 12b, according to one embodiment of the present invention. Figure 4 further illustrates that multiple transducers associated with sonotrodes 12a and 12b can be inserted into the same wine barrel 22. When multiple sonotrodes 12a and 12b are inserted into the same wine barrel 22 the transducer associated with each of the sonotrodes 12a and 12b are connected to the same generator 18, located in this example within the handle 14 of the ultrasonic processor 10.

[0025] Figure 5 illustrates a side cut away view of a wine barrel 22 that is completely or partially filled with water and has an exemplary ultrasonic processor 10 with a linear sonotrode 12 which has nodules 36 along its length, according to one embodiment of the present invention. These nodules 36 act as wave guides and help to amplify the resonance of the ultrasonics. The increased radial energy that is produced enhances the cleaning efficiency of the ultrasonics, especially on the interior surface of the end staves 24 of the barrel 22. [0026] Figure 6 illustrates a side cut away view of a wine barrel 22 that is completely or partially filled with water and has an exemplary ultrasonic processor 10 with an attached sensor 38 which can move semi independently from the sonotrode 12, according to one embodiment of the present invention. This sensor 38 monitors the ultrasonic activity 40 within the cavity of the wine barrel 22. This so called "smart" technology enhances the efficiency of the cleaning as it monitors ultrasonic activity and enables the operator to, where necessary, make changes to the process. These changes can include increasing the length of time that a particular stave 24 is exposed to the ultrasonic activity. [0027] Figure 7 illustrates a side cut away view of a wine barrel 22 that has an exemplary ultrasonic processor 10 with a series of sensors 42 located along the sonotrode 12 of the processor 18, according to one embodiment of the present invention. A series of sensors 42 located at various points along the sonotrode 12 enable improved monitoring of ultrasonic activity within the barrel 22, compared to a single sensor located at a fixed location within the wine barrel 22.

[0028] Figure 8 illustrates a side cut away view of a wine barrel that has an exemplary sonotrode positioned in water contained within a funnel, according to one embodiment of the present invention. Figure 8 shows an alternate embodiment where the sonotrode 12 of the ultrasonic processor 10 is located in an external column of water contained in a funnel 80 attached to the bunghole 20 with a watertight seal 82. The external column of water together with the water inside the barrel constitute a continuous body of water. [0029] It should be understood by the reader that the cables and pipes associated with the embodiments of the present invention are of a sufficient length to enable barrels to be cleaned in situ, even when the barrels are at a distance from power or water sources. Furthermore, the ultrasonic processor 10 can also be located on a boom to enable the user to manipulate the processor 10 with ease, even when the barrels 22 are stacked or on rollers high above the ground.

[0030] The use of ultrasonics is a cost effective way to clean wine barrels. The present apparatus and method avoids the need to completely dismantle the wine barrel or to remove one end of the barrel. The ability of ultrasonics to disinfect the interior surface of the wine barrel stave also means that the chances of cross contamination from bacteria and yeast are reduced. Furthermore, the ease with which the present invention can be used in conjunction with currently available equipment, such as barrel rollers, increases the likelihood of this technique being used by wineries. Added to these advantages are the reduction in cleaning time and the fact that less water is required for the cleaning process.

[0031] In numerous embodiments, a sonotrode is inserted into liquid within the wine barrel to effect cleaning. Depending on the strength of the cavitation energy and/or the size of the barrel it may be advantageous to be able to internally move the sonotrode. The movement may either be one or two-dimensional either defining an arc within the barrel and pivoting end to end or rotating in a circle within the wine barrel. Both movements have the effect of alternating the distance between the surface area to be cleaned and the transducer. The pivoting or rotational motion may be accomplished by well-known mechanical means such as an electric motor or even a motor operating on water pressure.

[0032] To save on water, the barrel may be rotated around its longitudinal axis to ensure that all of the inside surface of the barrel is exposed to ultrasonic cleaning activity. The rotation of the wine barrel may be achieved by using rollers or other similar techniques in the wine industry that are used in manipulating of wine barrels.

[0033] As discussed above, the application of ultrasonic energy to barrels may remove tartrate crystals that are encrusted on to the surface of oak wood barrels and suspend them, along with other residues (referred to as "lees") in the bottom of the barrels in which wine has been stored for periods of time. As a consequence of the tartrate removal, there will be better transfer of oak flavor to the wine. This ensures that the interior surface of an oak barrel is completely devoid of undesirable organics and inorganic matter which can be detrimental to wine quality.

The suspended substances are easily removed during the cleaning process. Cleaning with ultrasonics avoids heating costs and the uses of chemicals. There is less loss of wood compounds using high power ultrasonics as compared to high pressure hot or cold water sprays. As a result, a barrel's life can be extended, thus reducing the cost of replacing barrels. [0034] High power ultrasonics kills the spoilage yeast Brettanomyces . This organism and other spoilage yeasts, and bacteria are found in the pores and cracks of oak wood wine barrels, especially around the inner surface at the interior of the barrel. In the embodiment of a wood barrel this is the location where wine residue is found at the interior surface layers of the wood. The ability of high power ultrasonic energy to heat and disinfect liquid and solid substances permits inactivation of organisms found on the interior staves surfaces of oak barrels present and to the depth of up to 8 mm or more. Ultrasonic energy disinfection avoids the use of chemicals, such as sulphur dioxide and ozone.

[0035] Figure 9 illustrates a flow diagram of an exemplary process 900 of ultrasonic cleaning, according to one embodiment of the present invention. A fluid is placed in contact with a portion of an inner surface of a container (910). The fluid may be gas or liquid, such as water, according to one embodiment. An ultrasonic sonotrode is placed in contact with the fluid (920). Generally, this occurs within the container, where the container is a wine barrel having oak staves. The ultrasonic sonotrode is operated to clean and disinfect the inner surface of the container (930).

[0036] If the container is only partially full of fluid, it may be necessary to move the fluid to another portion of the inner surface of the container. The fluid may be moved by rotating the container, according to one embodiment. After cleaning, the ultrasonic sonotrode is removed from the container (940). This can be done both mechanically or physically. Once the container is clean and disinfected, any debris within the container is removed and the fluid is drained from the container (950).

[0037] The present apparatus and method avoid spoilt wine caused by contamination, improve transfer of oak flavor to the wine through reduced tartrate deposits in the barrels, avoid the loss of oak flavor through existing washing methods, lower barrel costs by avoiding replacing barrels spoilt by contamination, lower barrel costs by extending the usable life of barrels, lower labor costs for cleaning operations, lower water costs, avoid the of use of chemicals, and lower water heating costs. [0038] Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the present invention has been described with respect to specific examples and subsystems, it will be apparent to those of ordinary skill in the art that the invention is not limited to these specific examples or subsystems but extends to other embodiments as well. The present invention includes all of these other embodiments as specified in the claims that follow.

Claims

CLAIMS We claim:

1 . Art ultrasonic apparatus, comprising: a sonotrode placed within a bunghole of a barrel; an ultrasonic generator connected to the sonotrode; and an ultrasonic transducer connected to the ultrasonic generator and associated with the sonotrode.

2. The ultrasonic apparatus of claim 1, wherein the sonotrode is one of a hollow sonotrode and a solid sonotrode; and the sonotrode includes sides profiled to be one of parallel, concave, and convex.

3. The ultrasonic apparatus of claim 2, wherein the sonotrode includes an end that has an orientation of a plurality of orientations, the plurality of orientation including flat, normal or otherwise to a long axis, concave or convex normal or otherwise to the long axis, and of a symmetrical or asymmetrical reduced or constant section.

4. The ultrasonic apparatus of claim 1, wherein the ultrasonic transducer creates ultrasonic energy at frequencies within a range of 1OkHz to 200OkHz.

5. The ultrasonic apparatus of claim 1, wherein the ultrasonic transducer creates ultrasonic energy at frequencies within a range of 1OkHz to 4OkHz.

6. The ultrasonic apparatus of claim 1, further comprising an ultrasonic activity sensor adapted to indicate an amount of ultrasonic activity within the barrel.

7. The ultrasonic apparatus of claim 1, wherein the sonotrode is made from one of a plurality of materials, the plurality of materials including a titanium and a titanium composite.

8. A method for ultrasonic cleaning, comprising: placing a fluid in contact with a portion of an inner surface of a container; placing an ultrasonic sonotrode in contact with the fluid; and operating the ultrasonic sonotrode to clean the portion of the inner surface.

9. The method of claim 8, wherein operating the ultrasonic sonotrode comprises operating the ultrasonic sonotrode to induce ultrasonic cavitation within the fluid and clean the inner surface of the container.

10. The method of claim 8, further comprising disinfecting the portion of the inner surface.

11. The method of claim 9, further comprising rotating the container to place the fluid in contact with a next portion of the inner surface.

12. The method of claim 11, further comprising removing detritus from the container.

13. The method of claim 9, further comprising: attaching a neck of a funnel externally to a bunghole of the container in a watertight manner; filling the container and funnel with water; immersing the ultrasonic sonotrode in the water contained in the funnel; and operating the ultrasonic sonotrode to induce cavitation in the fluid thereby cleaning the inner surface of the container.

14. The method of claim 9, wherein placing the ultrasonic sonotrode comprises vertically placing the ultrasonic sonotrode within the container; and passing the ultrasonic sonotrode through a bunghole of the container through an intermediate flange.

15. The method of claim 9, further comprising positioning the ultrasonic sonotrode in communication with a transducer.

16. A system for ultrasonic cleaning, comprising: means for placing a fluid in contact with a portion of an inner surface of a container; means for placing an ultrasonic sonotrode in contact with the fluid; and means for cleaning the portion of the inner surface.

17. The system of claim 16, wherein means for operating the ultrasonic sonotrode comprises means for operating the ultrasonic sonotrode to induce ultrasonic cavitation within the fluid and clean the inner surface of the container.

18. The system of claim 16, further comprising means for disinfecting the portion of the inner surface.

19. The system of claim 17, further comprising means for rotating the container to place the fluid in contact with a next portion of the inner surface.

20. The system of claim 19, further comprising means for removing debris from the container.

21. The system of claim 17, further comprising: means for attaching a neck of a funnel externally to a bunghole of the container in a watertight manner; means for filling the container and funnel with water; means for immersing the ultrasonic sonotrode in the water contained in the funnel; and means for operating the ultrasonic sonotrode to induce cavitation in the fluid thereby cleaning the inner surface of the container.

22. The system of claim 17, wherein means for placing the ultrasonic sonotrode comprises vertically placing the ultrasonic sonotrode within the container; and means for passing the ultrasonic sonotrode through a bunghole of the container.

23. The system of claim 17, further comprising means for positioning the ultrasonic sonotrode in communication with a transducer.

24. A method to clean an interior of a wooden wine barrel having wine residue in the surface layers of an interior surface comprising introducing an ulrasonic transducer to the interior of the barrel though a bung hole; activating the transducer during rotation of the barrel to expose the surface layers of the inner surface to ultrasonic energy; and removing detritus resulting from exposure of the wine residue to the ultrasonic energy.