Controller and method for administering and providing on-line handling of deviations in a rotary sterilization process

A controller for administering a sterilization process performed by a rotary sterilizer on a continuous line of containers of containers, the controller comprising:

• control circuitry configured to control the rotary sterilizer;
• a memory configured to store a process control program and a deviation program, the process control program being programmed to cause the control circuitry to control the rotary sterilizer in performing the sterilization process according to scheduled parameters, the deviation programmed being programmed to identify, when a deviation in a specific one of the scheduled parameters occurs, those of the containers that will in response have a total lethality predicted to be delivered to them during the sterilization process that is less than a predefined target lethality;
• and
• a microprocessor coupled to the memory and the control circuitry and configured to execute the process control and temperature deviation programs.

A rotary sterilization system comprising:

• a rotary sterilizer configured to perform a sterilization process on a continuous line of containers;
• a controller configured to:
• control the rotary sterilizer in performing the rotary sterilization process according to scheduled parameters;
• when a deviation in a specific one of the scheduled parameters occurs, identify those of the containers that will in response have a total lethality predicted to be delivered to them during the sterilization process that is less than a predefined target lethality.

The rotary sterilization system of claim 26 wherein:

• the lethality predicted to be delivered over the second time interval is based on the portion of the product cold spot time-temperature profile over the second time interval;
• the scheduled parameters include one or more scheduled retort temperatures that are scheduled for the sterilization process in the second time interval;
• and
• the portion of the product cold spot time-temperature profile over the second time interval is based on the one or more scheduled retort temperatures.