Filling production system

Abstract

This invention relates to the field of beverage processing technology, and more particularly to a filling production system, comprising a liquid mixing device, a powder mixing device, a main conveying device, and a first filling device. The liquid mixing device includes a sealed liquid mixing tank protected by nitrogen as a backup pressure. The powder mixing device includes a vacuum mixer. The outlets of the liquid mixing tank and the vacuum mixer are both connected to the inlet of the main conveying device, and the outlet of the main conveying device is connected to the first filling device. This invention provides a flexible processing system for adding heat- and oxygen-sensitive substances and substances with special functions at a constant concentration with ultra-low loss. This solves the problems in the prior art where heat processing leads to thermal denaturation or inactivation of substances, and reduces the impact of oxygen on oxygen-sensitive substances through nitrogen protection. It also provides a better technical option for adding various functional nutritional additives.

Description

Technical Field

[0001] This invention relates to the field of beverage processing technology, and in particular to a filling production system. Background Technology

[0002] The content of bioactive substances in beverages, such as active proteins (immunoglobulins, lactoferrin, α-lactalbumin, β-lactoglobulin and colostrum basic protein, etc.), probiotics, enzymes (lactoperoxidase, lactase, etc.) and active ingredients from plant extracts, as well as fatty acids (such as Omega-3, Omega-6, etc.) to enhance concentration and memory, and protect the health of the human nervous system and retina, are all important. These substances are sensitive to oxygen, easily denatured or inactivated by heat, and easily oxidized, thus affecting their efficacy and product flavor. Therefore, their processing and production require strict requirements and special treatment.

[0003] To meet consumer demand for high-quality products, maintaining constant concentrations, minimizing losses, and preserving the original quality of special food additives such as vitamins, minerals (calcium, iron, zinc, etc.), flavorings and seasonings, and antioxidants remains a key technical challenge in processing. Since these substances are all high-value-added materials, with high costs and difficulty in obtaining them, ensuring constant additive concentrations and minimizing process losses is crucial for commercial production. Current technologies involve mixing sensitive and high-value-added materials with special functions before ultra-high temperatures. After high-intensity heat treatment, their functions and sensory effects change significantly, severely impacting consumer nutritional needs and sensory experiences. Summary of the Invention

[0004] This invention provides a filling production system to address one of the shortcomings of the prior art, thereby reducing the gas content in liquid materials and minimizing the adverse effects of oxidation caused by excessive oxygen content on material quality.

[0005] This invention provides a filling production system, including a liquid mixing device, a powder mixing device, a main conveying device, and a first filling device. The liquid mixing device includes a sealed liquid mixing tank protected by nitrogen as a backup pressure. The powder mixing device includes a vacuum mixer. The outlet of the liquid mixing tank and the outlet of the vacuum mixer are both connected to the inlet of the main conveying device. The outlet of the main conveying device is connected to the first filling device.

[0006] According to a filling production system provided by the present invention, the main conveying device includes a main conveying line formed by sequentially connecting a first valve body, a centrifugal separation device, a deep impurity removal filtration device, and an absolute sterilization device. The outlet of the liquid mixing device and the outlet of the powder mixing device are both connected to the inlet of the centrifugal separation device through the first valve body. The first outlet of the absolute sterilization device is connected to the first filling device.

[0007] According to a filling production system provided by the present invention, a recycling device is also included, wherein the second outlet of the absolute sterilization device is connected to the inlet of the recycling device, and the inlet of the liquid mixing tank is connected to the outlet of the recycling device.

[0008] According to a filling production system provided by the present invention, the recycling device includes a second valve body and a first online detector. The inlet of the first online detector is connected to the second outlet of the absolute sterilization device through the second valve body, and the outlet of the first online detector is connected to the inlet of the liquid mixing tank.

[0009] According to a filling production system provided by the present invention, the main conveying device further includes a third valve body, the outlet of the absolute sterilization device is connected to the inlet of the first filling device through the third valve body, and the third valve body is connected to the second valve body to form a secondary conveying line.

[0010] According to a filling production system provided by the present invention, the recycling device further includes a main recycling conveying line formed by sequentially connecting a fourth valve body, a membrane filter device, a second online detector, and a fifth valve body, and a secondary recycling conveying line formed by sequentially connecting the fifth valve body and the fourth valve body. The outlet of the first online detector is connected to the inlet of the membrane filter device through the fifth valve body, and the outlet of the second online detector is connected to the inlet of the liquid mixing tank through the fifth valve body.

[0011] According to a filling production system provided by the present invention, a basic mixing device and a second filling device are further included. The basic mixing device includes a basic mixing conveying line formed by sequentially connecting a batching tank, a centrifugal pump, a sterilization device and a static mixer, as well as a branch pipeline. The outlet of the static mixer is connected to the inlet of the second filling device. The pipeline connecting the sterilization device and the static mixer is connected to the outlet of the branch pipeline. The inlet of the branch pipeline is connected to the third valve body.

[0012] According to a filling production system provided by the present invention, a control device is further included, which is connected to the second valve body, the third valve body, the fourth valve body and the fifth valve body respectively.

[0013] According to a filling production system provided by the present invention, the powder mixing device further includes a smoothing pump, and the outlet of the vacuum mixer is connected to the inlet of the main conveying device through the smoothing pump.

[0014] According to a filling production system provided by the present invention, the first filling device includes an aseptic bag filling machine.

[0015] The filling production system provided by this invention uses a liquid mixing device to mix and convey liquid materials, and a powder mixing device to mix and convey powder materials. The outlets of both the liquid and powder mixing devices are connected to a main conveying device. The mixed liquid and powder then enter the main conveying device for further homogenization before being conveyed to the first filling device for filling. Compared to existing technologies that uniformly mix sensitive and high-value-added liquid and powder materials in a single mixing tank before ultra-high temperature treatment, this invention uses separate liquid and powder mixing devices to mix liquid and powder materials. This allows for independent and suitable mixing processing for different types of materials. Liquids and powders are processed using different methods based on their characteristics, improving mixing and emulsification effects while minimizing operating costs and avoiding changes in the functional effects of materials due to a uniform mixing method.

[0016] Heat- and oxygen-sensitive active liquid raw materials, as well as special functional high-value-added liquid raw materials, are mixed in a liquid mixing tank. This tank is sealed and protected by nitrogen, maintaining a closed state throughout production. Feeding is done according to production batches, effectively preventing external gases from entering the tank and reducing the gas content in the liquid material. This minimizes oxidation reactions caused by excessive oxygen content, reducing the adverse effects on material quality. Heat- and oxygen-sensitive active powder raw materials, as well as special functional high-value-added powder raw materials, are mixed using a vacuum mixer. The vacuum mixer operates under negative pressure, resulting in materials with low oxygen content, meeting the requirements for powder raw material processing. This solves the current production process's lack of attention to oxygen-sensitive substances, limited processing methods, and significant oxidation reactions, especially for fatty acids, which result in decreased functional effects and severe flavor changes after processing.

[0017] This invention provides a flexible processing system for adding heat-, oxygen-sensitive, and special functional substances at a constant concentration with ultra-low loss. This system addresses the problems in existing technologies where heat processing leads to thermal denaturation or deactivation of these substances, and reduces the impact of oxygen on oxygen-sensitive substances through nitrogen protection. It also provides a better technical option for adding various functional nutritional additives.

[0018] In addition to the technical problems solved by the present invention, the technical features of the technical solutions constituted by the present invention, and the advantages brought about by the technical features of these technical solutions as described above, other technical features of the present invention and the advantages brought about by these technical features will be further explained in conjunction with the accompanying drawings, or will be learned through the practice of the present invention. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the filling production system provided by the present invention.

[0021] Figure label:

[0022] 100. Liquid mixing device; 110. Liquid mixing tank; 120. First twin-screw pump; 130. Liquid feeding hopper;

[0023] 200. Powder mixing device; 210. Vacuum mixer; 220. Smoothing pump; 230. Powder feeding hopper; 240. Third twin-screw pump; 250. Sixth valve body;

[0024] 300. Main conveying device; 310. First valve body; 320. Centrifugal separation device; 330. Deep impurity removal filtration device; 340. Absolute sterilization device; 350. Third valve body; 360. Third online detector; 370. First flow meter; 380. Second twin-screw pump; 390. Main conveying line; 3100. Auxiliary conveying line;

[0025] 400. First filling device;

[0026] 500. Recycling device; 510. Second valve body; 520. First online detector; 530. Fourth valve body; 540. Membrane filtration device; 550. Second online detector; 560. Fifth valve body; 570. Main recycling conveyor line; 580. Auxiliary recycling conveyor line;

[0027] 600. Basic mixing device; 610. Batching tank; 620. Centrifugal pump; 630. Sterilization device; 640. Static mixer; 650. Branch pipeline; 660. Second flow meter;

[0028] 700. Second filling device;

[0029] 800. Control device; 810. PLC control system; 820. Online control module. Detailed Implementation

[0030] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0031] In the description of the embodiments of the present invention, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0032] In the description of the embodiments of the present invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of the present invention based on the specific circumstances.

[0033] In embodiments of the present invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0034] Furthermore, in the description of the embodiments of the present invention, unless otherwise stated, "multiple", "multiple roots", and "multiple groups" mean two or more, and "several", "several roots", and "several groups" mean one or more.

[0035] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0036] like Figure 1 As shown, the filling production system provided in this embodiment of the invention includes a liquid mixing device 100, a powder mixing device 200, a main conveying device 300, and a first filling device 400. The liquid mixing device 100 includes a sealed liquid mixing tank 110 protected by nitrogen as a backup pressure. The powder mixing device 200 includes a vacuum mixer 210. The outlet of the liquid mixing tank 110 and the outlet of the vacuum mixer 210 are both connected to the inlet of the main conveying device 300. The outlet of the main conveying device 300 is connected to the first filling device 400.

[0037] The filling production system of this invention uses a liquid mixing device 100 to mix and convey liquid materials, and a powder mixing device 200 to mix and convey powder materials. The outlets of both the liquid mixing device 100 and the powder mixing device 200 are connected to a main conveying device 300. The mixed liquid and powder then enter the main conveying device 300 for further homogenization, and finally are conveyed by the main conveying device 300 to the first filling device 400 for filling. Compared to existing technologies that uniformly mix sensitive and high-value-added liquid and powder materials in a single mixing tank before ultra-high temperature treatment, this invention uses separate mixing devices 100 and 200 to mix liquid and powder materials. This allows for independent and suitable mixing processing for different types of materials. Liquids and powders are processed using different methods based on their characteristics, improving mixing and emulsification effects while minimizing operating costs and avoiding changes in the functional effects of materials due to a uniform mixing method.

[0038] Heat- and oxygen-sensitive active liquid raw materials, as well as special functional high-added-value liquid raw materials, are mixed in a liquid mixing tank 110. The liquid mixing tank 110 is a sealed tank protected by nitrogen, maintaining a closed state throughout the production process. Feeding is done according to production batches, effectively preventing external gases from entering the mixing tank, reducing the gas content in the liquid materials, and minimizing oxidation reactions caused by excessive oxygen content, which could adversely affect material quality. Heat- and oxygen-sensitive active powder raw materials, as well as special functional high-added-value powder raw materials, are mixed in a vacuum mixer 210. The vacuum mixer 210 operates under negative pressure, resulting in materials with low oxygen content, meeting the requirements for powder raw material processing. This solves the current production process's lack of attention to oxygen-sensitive substances, limited processing methods, and significant oxidation reactions, especially for fatty acids, which result in decreased functional effects and severe flavor changes after processing.

[0039] This invention provides a flexible processing system for adding heat-, oxygen-sensitive, and special functional substances at a constant concentration with ultra-low loss. This system addresses the problems in existing technologies where heat processing leads to thermal denaturation or deactivation of these substances, and reduces the impact of oxygen on oxygen-sensitive substances through nitrogen protection. It also provides a better technical option for adding various functional nutritional additives.

[0040] In this embodiment, the powder is fed into the vacuum mixer 210 through the powder feeding hopper 230, and the powder raw material is sucked into the vacuum mixer 210 for mixing by utilizing the negative pressure principle.

[0041] In this embodiment, the liquid mixing device 100 also includes a first twin-screw pump 120 and a liquid feeding hopper 130. The liquid feeding hopper 130 feeds the liquid mixing tank 110. After the liquid material is mixed in the liquid mixing tank 110, it enters the main conveying device 300 through the liquid conveying line under the drive of the first twin-screw pump 120.

[0042] According to an embodiment of the present invention, the main conveying device 300 includes a main conveying line 390 formed by sequentially connecting a first valve body 310, a centrifugal separator 320, a deep impurity removal filter 330, and an absolute sterilization device 340. The outlets of the liquid mixing device 100 and the powder mixing device 200 are both connected to the inlet of the centrifugal separator 320 via the first valve body 310. The first outlet of the absolute sterilization device 340 is connected to the first filling device 400. In this embodiment, the liquid material uniformly mixed by the liquid mixing device 100 and the powder material uniformly mixed by the powder mixing device 200 enter the main conveying device 300 through the first valve body 310. After being processed sequentially by the centrifugal separator 320, the deep impurity removal filter 330, and the absolute sterilization device 340 along the conveying direction of the main conveying line 390, the material is finally sent to the first filling device 400 for filling.

[0043] Heat- and oxygen-sensitive active materials, as well as high-value-added materials with special functions, require complex separation or extraction processes. Due to the high technical difficulty and bottlenecks in these processes, it is difficult to obtain 100% pure raw materials, thus all raw materials may be contaminated with other impurities. Even with different methods of processing liquid or powder raw materials, it is impossible to achieve completely uniform particle size. This can cause blockage of the absolute sterilization device 340 during the absolute sterilization process, affecting production efficiency and increasing the replacement cost of the filter element in the absolute sterilization device 340. To effectively solve the above problems and improve the permeability of materials through the absolute sterilization device 340, this invention uses a combination of a centrifugal separation device 320 and a deep impurity removal filtration device 330 for pre-sterilization, thereby effectively improving the membrane permeability of the material and achieving better sterilization results.

[0044] Centrifugal separation and deep impurity removal filtration have different principles and different processing targets. Centrifugal separation alone has limited processing effect, and deep impurity removal filtration alone has limited extension of continuous operation time. This invention combines centrifugal separation device 320 and deep impurity removal filtration device 330 to process materials on the main conveyor line 390, effectively extending the operation time of deep impurity removal filtration and absolute sterilization filter cartridge, and improving production efficiency.

[0045] In existing production processes, at least two absolute sterilization devices 340 are required depending on the amount of material to be processed. The filter housings include sizes such as 5-inch, 10-inch, 20-inch, and 30-inch. While the 5-inch filter housing is small and has low material loss, it has a limited processing capacity. Therefore, existing production lines often use 20-inch or larger filter cartridges, resulting in high material loss per cartridge. In this invention, the material pre-treated by the centrifugal separation device 320 and the deep impurity removal filtration device 330 enters the absolute sterilization device 340. The filter cartridge in the absolute sterilization device 340 is a biological-grade absolute sterilization filter cartridge, and the material treated by it achieves commercial sterility.

[0046] In this embodiment, the main conveying device 300 further includes a third online detector 360, a first flow meter 370, and a second twin-screw pump 380. The third online detector 360 detects the concentration of material entering the main conveying line 390, the first flow meter 370 detects the flow rate of material conveyed by the main conveying line 390, and the second twin-screw pump 380 provides driving force for the conveying of material within the main conveying line 390. The third online detector 360, the first flow meter 370, the centrifugal separator 320, the deep impurity removal filter 330, the second twin-screw pump 380, and the absolute sterilization device 340 are sequentially connected along the main conveying line 390.

[0047] According to one embodiment of the present invention, the filling production system further includes a recycling device 500. The second outlet of the absolute sterilization device 340 is connected to the inlet of the recycling device 500, and the inlet of the liquid mixing tank 110 is connected to the outlet of the recycling device 500. In this embodiment, the top of the absolute sterilization device 340 is provided with a second outlet, which is connected to the inlet of the liquid mixing tank 110 through the recycling device 500. That is, the material in the absolute sterilization device 340 can return to the liquid mixing tank 110 through the second outlet and the recycling device 500, thereby circulating the material.

[0048] At the start of production, the filter element in the absolute sterilization device 340 is first moistened with purified water. Once the filter shell is completely filled with purified water, material is passed through, i.e., material flushing. At this point, the entire main conveyor line 390 is filled with purified water. To ensure a constant material concentration, previously, the mixture of material and purified water was directly discharged through the second outlet of the absolute sterilization device 340 during production, resulting in material loss during flushing. Furthermore, after production ends, the absolute sterilization device 340 still contains material. However, currently, because a constant material concentration cannot be guaranteed after production, the material remaining in the absolute sterilization device 340 is not recycled but directly discharged, also causing significant material loss. Due to the special nature of the materials—all high-value-added substances with complex extraction processes, high acquisition difficulty, high costs, and small material quantities—this invention, by setting up a recycling device 500 for effective recycling and reducing material loss, is of great significance for cost savings and large-scale production.

[0049] Understandably, the absolute sterilization device 340 has an inlet and a first outlet at the bottom and a second outlet at the top. During the process of material flushing, the pure water that fills the filter shell gradually pushes out the material that enters from the bottom inlet until the filter shell is completely filled with material, and no pure water residue affects the material concentration.

[0050] After undergoing high-intensity heat treatment, its function and sensory effects change significantly, seriously affecting consumers' nutritional needs and sensory experience.

[0051] According to one embodiment of the present invention, the recovery device 500 includes a second valve body 510 and a first online detector 520. The inlet of the first online detector 520 is connected to the second outlet of the absolute sterilization device 340 through the second valve body 510, and the outlet of the first online detector 520 is connected to the inlet of the liquid mixing tank 110. In this embodiment, the second valve body 510 and the first online detector 520 are sequentially installed on the pipeline connecting the second outlet of the absolute sterilization device 340 and the inlet of the liquid mixing tank 110. The first online detector 520 is used to accurately determine whether there is material in the liquid flowing out of the absolute sterilization device 340. For the detection of protein materials, ultraviolet detection can be used to determine whether recovery should start. If recovery starts, the second valve body 510 is opened; otherwise, the second valve body 510 is closed.

[0052] During the material flushing process, existing technologies typically rely on human experience to determine whether there is only material and no purified water in the conveying pipeline of the recovery device 500. This leads to material loss or fluctuations in material concentration during flushing. To effectively recover the material within the main conveying device 300 during material filling and production termination in the absolute sterilization device 340, direct discharge is replaced with online recovery. Traditional processing relies mainly on human judgment of concentration, resulting in product concentration fluctuations. To ensure the concentration meets the labeled value, some products often use excessive additives, increasing production costs. Therefore, this invention uses a first online detector 520 for real-time monitoring to ensure a constant additive concentration in the recovery device 500 and reduce material loss during the recovery process.

[0053] According to one embodiment of the present invention, the main conveying device 300 further includes a third valve body 350. The outlet of the absolute sterilization device 340 is connected to the inlet of the first filling device 400 through the third valve body 350. The third valve body 350 and the second valve body 510 are connected to form a secondary conveying line 3100. In this embodiment, the third valve body 350 is provided on the pipeline connecting the absolute sterilization device 340 and the first filling device 400. At the same time, the third valve body 350 and the second valve body 510 are also connected to form the secondary conveying line 3100 of the main conveying device 300. The material in the absolute sterilization device 340 is sent to the recovery device 500 through the secondary conveying line 3100 and returns to the liquid mixing tank 110.

[0054] In actual production, the pipeline distance between the absolute sterilization device 340 and the first filling device 400 is very long. Therefore, even if the material flushing work in the absolute sterilization device 340 has been completed, the liquid in this section of the pipeline may contain pure water or the material concentration may not meet the standards, which will also affect the material concentration. Moreover, when production ends, the material in this section of the pipeline is often directly discharged at the third valve body 350, which will also cause material loss. This invention designs a secondary conveying line 3100 at the third valve body 350 to send the material in the pipeline between the absolute sterilization device 340 and the first filling device 400 to the recovery device 500. When material recovery is needed, the secondary conveying line 3100 connects the main conveying line 390 to the recovery device 500. When production is needed, the main conveying line 390 connects to the first filling device 400 to realize automatic switching between production and recovery.

[0055] During the material top-water process, the third valve body 350 is first connected to the second valve body 510 via the auxiliary conveyor line 3100. The first online detector 520 determines whether to start recycling and whether to start production. If there is low concentration of material, recycling mode is started. When the material concentration is consistent with the target concentration, the third valve body 350 automatically switches to production mode. Similarly, when production ends, the first online detector 520 determines to end recycling. Recycling ends when no material can be detected, thereby effectively improving recycling efficiency.

[0056] According to an embodiment of the present invention, the recycling device 500 further includes a main recycling conveying line 570 formed by sequentially connecting a fourth valve body 530, a membrane filtration device 540, a second online detector 550, and a fifth valve body 560, and a secondary recycling conveying line 580 formed by sequentially connecting the fifth valve body 560 and the fourth valve body 530. The outlet of the first online detector 520 is connected to the inlet of the membrane filtration device 540 through the fifth valve body 560, and the outlet of the second online detector 550 is connected to the inlet of the liquid mixing tank 110 through the fifth valve body 560. In this embodiment, the membrane filtration device 540 and the second online detector 550 are sequentially connected to form the main recycling conveying line 570. The fourth valve body 530 and the fifth valve body 560 are designed at both ends of the main recycling conveying line 570, and the fourth valve body 530 and the fifth valve body 560 are independently connected through the secondary recycling conveying line 580, that is, the main recycling conveying line 570 and the secondary recycling conveying line 580 form a parallel pipeline. After the material passes through the first online detection, it can be divided into two paths at the fourth valve body 530. One path goes through the auxiliary recovery conveyor line 580 and then to the fifth valve body 560 to enter the liquid mixing tank 110. The other path goes through the main recovery conveyor line 570 and then through the fifth valve body 560 to enter the liquid mixing tank 110.

[0057] Because the concentration of the recovered materials fluctuates, a membrane filtration device 540 is installed on the main recovery conveyor line 570 to concentrate low-concentration materials in order to ensure a constant final material concentration and avoid material concentration fluctuations during actual production. The type of membrane filtration is selected based on the molecular weight or particle size of the material. For example, ultrafiltration is used for protein materials, while reverse osmosis is used for small molecule materials such as fragrances and flavorings. Reverse osmosis can also be used, but its concentration efficiency for protein materials will be reduced.

[0058] The first online detector 520 at the front end of the membrane filtration unit 540 automatically determines whether membrane concentration is required. If concentration is not required, the recovered material directly enters the liquid mixing tank 110 through the fourth valve body 530, the auxiliary recovery conveyor line 580, and the fifth valve body 560. If the material does not reach the target concentration, it needs to be concentrated by the membrane filtration unit 540. The material concentrated by the membrane filtration unit 540 needs to be further determined by the second online detector 550 at the rear end of the membrane filtration unit 540 to determine whether the target concentration has been reached. If it has, it enters the liquid mixing tank 110 through the fifth valve body 560; if it has not, after passing through the fifth valve body 560, it passes through the auxiliary recovery conveyor line 580 again, returns to the fourth valve body 530, and then re-enters the membrane filtration unit 540 for further concentration.

[0059] According to one embodiment of the present invention, the filling production system further includes a basic mixing device 600 and a second filling device 700. The basic mixing device 600 includes a basic mixing conveying line formed by sequentially connecting a batching tank 610, a centrifugal pump 620, a sterilization device 630, and a static mixer 640, as well as a branch pipeline 650. The outlet of the static mixer 640 is connected to the inlet of the second filling device 700. The pipeline connecting the sterilization device 630 and the static mixer 640 is connected to the outlet of the branch pipeline 650. The inlet of the branch pipeline 650 is connected to a third valve body 350. In this embodiment, based on the liquid mixing device 100, powder mixing device 200, recovery device 500, main conveying device 300, and first filling device 400, a basic mixing device 600, a second filling device 700, and a branch pipeline 650 are added. After mixing and distributing the materials in the basic mixing device 600 via the mixing tank 610, the materials in the mixing pipe are then pumped by the centrifugal pump 620 into the sterilization device 630 to kill pathogens, pathogens, and spores. After the product meets commercial sterility requirements, the materials are sent to the second filling device 700. The branch pipeline 650 connects the third valve body 350 to the front end of the static mixer 640. The sterilized materials mixed in the main conveying device 300 are then sent together with the materials from the sterilization device 630 into the static mixing device for further mixing. Finally, the second filling device 700 fills the materials into the specified packaging for aseptic filling and shipment.

[0060] In this embodiment, to adapt to actual production needs, the material in the total conveying device 300 of this application is mixed with the output material of the basic mixing device 600 in the conventional mixing process, and then filled and shipped out. By using different processing methods to achieve the commercial sterility requirements of liquid mixing, the pressure on the production line is shared, the product quality is improved, and it can also adapt to the construction of the production line.

[0061] In one embodiment, the basic mixing device 600 further includes a second flow meter 660, which is designed at the back end of the sterilization system to detect the material flow rate of the entire basic mixing device 600.

[0062] According to one embodiment of the present invention, the filling production system further includes a control device 800, which is connected to the second valve body 510, the third valve body 350, the fourth valve body 530, and the fifth valve body 560, respectively. In this embodiment, the second valve body 510, the third valve body 350, the fourth valve body 530, and the fifth valve body 560 can all be three-way reversing valves. The control device 800 controls the opening, closing, and reversing operations of each valve body based on the detection results of the first online detector 520 and the second online detector 550. The application of the online detection and online control system of the present invention can reduce the number of material storage tanks and make the control of physicochemical data more precise.

[0063] In this embodiment, the control device 800 includes a PLC control system 810 and an online control module 820. The PLC control system 810 is communicatively connected to each valve body through the online control module 820 corresponding to each valve body.

[0064] According to one embodiment of the present invention, the powder mixing device 200 further includes a smoothing pump 220, and the outlet of the vacuum mixer 210 is connected to the inlet of the main conveying device 300 through the smoothing pump 220. In this embodiment, since the amount of heat- and oxygen-sensitive active powder raw materials and special functional high-added powder raw materials is small and the cost is high, the mixing process in the vacuum mixer 210 is made as smooth as possible to reduce irreversible mechanical damage to the raw materials caused by strong shear. However, the powdering process is difficult, and low shear may pose a risk of raw material agglomeration. Therefore, a smoothing pump 220 is separately configured on the discharge pipeline to enhance the emulsification effect of the material and meet the requirements of subsequent processing.

[0065] In this embodiment, the powder mixing device 200 also includes a sixth valve body 250 and a third twin-screw pump 240. The outlet of the vacuum mixer 210, the sixth valve body 250, the third twin-screw pump 240, the smooth pump 220 and the first valve body 310 are connected in sequence. At the same time, the sixth valve body 250 is also connected to the top feed port of the vacuum mixer 210. That is, the powder material sent out from the vacuum mixer 210 can be transported by two routes. One route is to pass through the sixth valve body 250 and be sent out through the third twin-screw pump 240. The other route is to pass through the sixth valve body 250 and return to the vacuum mixer 210 for recycling.

[0066] Due to the sensitivity of the above materials, twin-screw pumps are used for material handling in the process to further reduce losses caused by mechanical shearing.

[0067] According to one embodiment of the present invention, the first filling device 400 includes an aseptic bag filling machine. In this embodiment, due to the small amount of material and high cost, it is desirable to reduce material loss. Direct backfilling to the product requires the product to be as close to the filling machine as possible. However, due to limitations imposed by the actual production plant's equipment layout and cleanliness level differences, the absolute sterilization device 340 is often far from the filling machine, and the pipeline is long. Therefore, the material is filled into aseptic bags using the aseptic bag filling machine, which facilitates subsequent use and makes the process more flexible. Using an aseptic bag filling machine for pre-filling aseptic bags can avoid the limitations caused by the production line equipment layout and flexibly meet the needs of different production processes.

[0068] In this embodiment, the aseptic bag filling machine is highly flexible and can flexibly meet the filling needs of materials with various viscosities. It offers a wide range of packaging specifications, including 5L, 10L, 20L, and even larger sizes such as 500L and 1000L.

[0069] When using the valve, it is not limited to whether the valve body is a gate valve, electric valve, solenoid valve or other type of valve that can be switched on or off.

[0070] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A filling production system, characterized in that: The system includes a liquid mixing device, a powder mixing device, a main conveying device, and a first filling device. The liquid mixing device includes a sealed liquid mixing tank protected by nitrogen pressure. The powder mixing device includes a vacuum mixer. The outlets of the liquid mixing tank and the vacuum mixer are both connected to the inlet of the main conveying device, and the outlet of the main conveying device is connected to the first filling device. The main conveying device includes a main conveying line formed by a first valve body, a centrifugal separator, a deep impurity removal filter, and an absolute sterilization device connected in sequence. It also includes a recovery device. The second outlet of the absolute sterilization device is connected to the inlet of the recovery device, and the inlet of the liquid mixing tank is connected to the outlet of the recovery device. The recovery device includes a second valve body and a first online detector. The inlet of the first online detector is connected to the second outlet of the absolute sterilization device through the second valve body, and the outlet of the first online detector is connected to the inlet of the liquid mixing tank.

2. The filling production system according to claim 1, characterized in that: The outlets of the liquid mixing device and the powder mixing device are both connected to the inlet of the centrifugal separation device through the first valve body, and the first outlet of the absolute sterilization device is connected to the first filling device.

3. The filling production system according to claim 2, characterized in that: The main conveying device also includes a third valve body. The outlet of the absolute sterilization device is connected to the inlet of the first filling device through the third valve body. The third valve body and the second valve body form a secondary conveying line.

4. The filling production system according to claim 3, characterized in that: The recovery device also includes a main recovery conveyor line formed by sequentially connecting a fourth valve body, a membrane filter, a second online detector, and a fifth valve body, as well as a secondary recovery conveyor line formed by sequentially connecting the fifth valve body and the fourth valve body. The outlet of the first online detector is connected to the inlet of the membrane filter through the fifth valve body, and the outlet of the second online detector is connected to the inlet of the liquid mixing tank through the fifth valve body.

5. The filling production system according to claim 4, characterized in that: It also includes a basic mixing device and a second filling device. The basic mixing device includes a basic mixing conveying line formed by sequentially connecting a batching tank, a centrifugal pump, a sterilization device, and a static mixer, as well as a branch pipeline. The outlet of the static mixer is connected to the inlet of the second filling device. The pipeline connecting the sterilization device and the static mixer is connected to the outlet of the branch pipeline. The inlet of the branch pipeline is connected to the third valve body.

6. The filling production system according to claim 5, characterized in that: It also includes a control device, which is connected to the second valve body, the third valve body, the fourth valve body and the fifth valve body respectively.

7. The filling production system according to any one of claims 1 to 6, characterized in that: The powder mixing device also includes a smoothing pump, and the outlet of the vacuum mixer is connected to the inlet of the main conveying device through the smoothing pump.

8. The filling production system according to any one of claims 1 to 6, characterized in that: The first filling device includes an aseptic bag filling machine.

Images