Multistage progressive sterilization process and equipment for mineral water

Abstract

The invention provides a multistage progressive sterilization process and equipment for mineral water, and relates to the technical field of mineral water production. The invention relates to a multi-stage progressive sterilization process for mineral water, which comprises the following steps: pretreatment of raw material water, multi-stage filtration and preliminary sterilization, branching deep sterilization and filling, whole-process quality control and waste classification treatment, and through progressive sterilization of ultrafiltration interception, double UV inactivation and branching ozone oxidation, the sterilization thoroughness and flavor retention are both considered; sterilization, filling and bottle cap disinfection schemes are customized for three types of volume products, the production suitability is improved, OPRP pre-control and CCP key control are combined, multi-dimensional detection and PLC linkage are matched, full rejection, classified recovery and resourceful treatment of unqualified products are combined, and resource waste and environmental pollution risks are reduced.

Description

Technical Field

[0001] This application relates to the field of mineral water production technology, and more specifically, to a multi-stage progressive sterilization process and equipment for mineral water. Background Technology

[0002] In mineral water production, microbial control is crucial for ensuring product safety and shelf life. Existing sterilization processes have significant limitations: First, they rely on single-stage UV or ozone sterilization, which can lead to incomplete sterilization or damage to natural flavor. Second, they lack differentiated adaptation for different packaging sizes (small bottles, medium bottles, large containers), resulting in poor production adaptability. Third, sterilization is loosely integrated with filtration, filling, and quality control processes, failing to form a comprehensive quality control system. Fourth, the disposal of waste bottles and caps lacks standardized classification, easily leading to resource waste or cross-contamination. Therefore, there is an urgent need for a sterilization process and equipment that balances sterilization effectiveness with flavor preservation, is adaptable to multi-volume production, and features closed-loop quality control. Summary of the Invention

[0003] This application aims to at least solve one of the technical problems existing in the prior art. To this end, this application proposes a multi-stage progressive sterilization process for mineral water, comprising the following steps:

[0004] S1. Raw water pretreatment: After obtaining groundwater, it is sequentially aerated, filtered by manganese sand and then filtered by quartz sand, and then cooled to room temperature by a plate exchanger.

[0005] S2. Multi-stage filtration and preliminary sterilization: The pretreated raw water is filtered through fine filtration and ultrafiltration membranes in sequence, and then sterilized by UV lamps to obtain primary purified water;

[0006] S3. Deep sterilization and filling by separate production lines: The primary purified water is transported to three production lines. Line 1 is suitable for 360ml / 500ml / 1.5L products, Line 2 is suitable for 4.5L / 15L products, and Line 3 is suitable for 17.9L bottled water. Each line is deeply sterilized by an ozone mixing unit, and then filling and capping are completed accordingly.

[0007] S4. Full-process quality control: Defective products are removed through PET visual inspection, light inspection, and label visual inspection. Qualified products are packaged, inkjet-printed, and palletized before being put into storage.

[0008] S5. Waste sorting and processing: Collect discarded empty bottles, bottle caps, labels, cardboard boxes, and films separately, store them temporarily, and then sell them off-site.

[0009] In addition, the multi-stage progressive sterilization process and equipment for mineral water according to the embodiments of this application also have the following additional technical features:

[0010] Preferably, the UV lamp sterilization in S2 uses a dual UV lamp series configuration.

[0011] Preferably, the ozone concentration of the ozone mixing unit in S3 is adjusted according to the product capacity of the corresponding production line.

[0012] Preferably, the manganese sand filtration and quartz sand filtration in S1 use graded filter media to achieve step-by-step impurity removal.

[0013] Preferably, after sealing in step S3, laser marking is added. The marking information includes key production parameters, and the clarity is verified by visual inspection.

[0014] Preferably, the bottle cap disinfection methods of each production line in S3 are set differently: Line 1 uses chlorine water disinfection, Line 2 uses ozone water disinfection, and Line 3 uses a combination of chlorine water and chlorine dioxide disinfection.

[0015] Preferably, the quality control in S4 also includes weighing and detecting the bags, and determining that the packages exceeding the preset error range are unqualified and rejected.

[0016] Preferably, the waste products mentioned in S5 are collected and sorted through a dedicated channel, the empty bottles are crushed, and the waste labels and waste films are compressed, packaged, and sold.

[0017] The beneficial effects of a multi-stage progressive sterilization process and equipment for mineral water according to an embodiment of this application are:

[0018] 1. Multi-stage synergistic sterilization: Through a progressive sterilization process of "ultrafiltration retention + dual UV inactivation + segmented ozone oxidation", it balances thorough sterilization with flavor preservation.

[0019] 2. Adaptive production lines: Customized sterilization, filling, and cap disinfection solutions for three types of product volumes to improve production adaptability;

[0020] 3. Closed-loop quality control, combining OPRP pre-control with CCP key control, coupled with multi-dimensional detection and PLC linkage, to achieve complete rejection of non-conforming products;

[0021] 4. Green waste management combines sorting and recycling with resource recovery to reduce resource waste and environmental pollution risks.

[0022] On the other hand, this application also provides a multi-stage progressive sterilization device for mineral water, comprising:

[0023] Raw water pretreatment unit: connected in sequence to an aeration device, a manganese sand filter, a quartz sand filter, a plate exchanger, and a raw water tank;

[0024] Multi-stage purification and sterilization unit: sequentially connected fine filter, ultrafiltration membrane module, dual UV lamp sterilization device and purified water tank;

[0025] Production lines: Lines 1, 2 and 3 are respectively equipped with ozone mixers, filling machines and capping machines. Line 3 is additionally equipped with a film cutting and capping integrated machine, a spraying device and a high-pressure internal washing machine.

[0026] Quality control unit: includes PET visual inspection instrument, light inspection machine, label visual inspection instrument, weighing sensor and non-conforming product rejection device;

[0027] Packaging and warehousing unit: sequentially connected labeling machine / sleeve shrink wrapping machine, sleeve handle device, packaging machine, inkjet printer, palletizer and warehousing equipment;

[0028] Waste processing unit: includes sorting and collection bins, crushing equipment, compression baler and waste temporary storage warehouse.

[0029] Preferably, the production line unit and the quality control unit are linked through a PLC control system. When the quality control unit detects a defective product, the PLC controls the key process of the corresponding production line to pause, and resumes operation after the defective product is removed. Attached Figure Description

[0030] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0031] Figure 1 This is a process flow diagram based on an embodiment of this application;

[0032] Figure 2 This is a flow chart of a first type of raw water treatment according to an embodiment of this application;

[0033] Figure 3 This is a second raw water treatment process flow diagram according to an embodiment of this application;

[0034] Figure 4 This is a flowchart of a first-line production unit according to an embodiment of this application;

[0035] Figure 5 This is a flowchart of a two-line production unit according to an embodiment of this application;

[0036] Figure 6 This is a flowchart of a three-line production unit according to an embodiment of this application. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0038] The following describes in detail, through specific embodiments, a multi-stage progressive sterilization process and equipment for mineral water according to the present invention.

[0039] The device composition and linkage relationship of the present invention:

[0040] The equipment of this invention is divided into 6 major units according to function. Each unit is connected in series according to the process of "raw materials → purification → sterilization → filling → quality control → warehousing". The linkage is achieved through pipelines, conveyor belts and PLC system. The specific configuration and corresponding process flow diagram are marked as follows:

[0041] Raw water pretreatment unit: B0 Groundwater acquisition device (OPRP1), B1 Aeration device, B2 / B11 Manganese sand filter, B5 Quartz sand filter (OPRP), B3 Plate exchanger, B4 Old raw water tank, B10 New raw water tank.

[0042] Multi-stage purification and sterilization unit: B6 / B12 fine filter, B7 / B15 ultrafiltration membrane module (OPRP2), B8 / B16 dual UV lamp sterilization device (OPRP3), B9 intermediate water tank, B17 ultrafiltration water tank;

[0043] Production line unit:

[0044] Line 1 (360ml / 500ml / 1.5L): B20 Ozone Mixer (CCP1), B24 Filler (CCP2), B25 Capper (OPRP4);

[0045] Line 2 (4.5L / 15L): B21 Ozone Mixer (CCP1), B37 Filling Machine (CCP2), B38 Capping Machine (OPRP5);

[0046] Line 3 (17.9L): B51 film cutting and capping integrated machine, B52 spraying device, B55 high-pressure internal washing machine, B56 alkaline washing device, B57 chemical washing device, B58 ozone mixer (CCP1), B60 filling machine (CCP2), B61 capping machine.

[0047] Quality control unit: B27 PET visual inspection instrument, B29 / B43 / B62 light inspection machine, B30 label visual inspection instrument, B32 weighing sensor, C1 non-conforming product rejection device;

[0048] Packaging and warehousing unit: B28 / B41 labeling machine, B42 handle device, B31 / B47 packaging machine, B33 / B48 / B65 inkjet printer, B34 / B49 palletizer, B22 / B23 / B35 / B46 / B50 / B68 warehousing equipment;

[0049] Waste processing unit: C2 waste storage bin, C3 takeaway processing device, crushing device, and compression baler.

[0050] like Figures 1-6 As shown, the process execution flow of the present invention is as follows:

[0051] S1. Raw water pretreatment (OPRP pretreatment)

[0052] After groundwater is obtained through B0, it enters the B1 aeration device to remove volatile substances, then passes through the B2 / B11 manganese sand filter to remove iron and manganese impurities, and then passes through the B5 quartz sand filter to filter suspended solids (OPRP point control); the filtered water flows through the B3 plate exchanger to be cooled to room temperature, and is stored in the B4 old raw water tank and the B10 new raw water tank respectively.

[0053] S2. Multi-stage purification and preliminary sterilization (OPRP key pre-control)

[0054] Water in the raw water tank is filtered by the B6 / B12 fine filter to remove fine particles, and then passes through the B7 / B15 ultrafiltration membrane module to retain colloids and some microorganisms (OPRP2 control); the ultrafiltration water enters the B8 / B16 dual UV lamp sterilization device for preliminary sterilization (OPRP3 control), and the treated primary purified water is stored in the B17 ultrafiltration water tank.

[0055] S3. Separate deep sterilization and filling (CCP critical control)

[0056] Line 1 production: Primary purified water enters the B20 ozone mixer for deep sterilization (CCP1 control), and then is injected into PET bottles through the B24 filling machine (the preforms are received by A3, blown by A10, and ionized by A4 dust removal). After filling, the bottles are capped by the B25 capping machine (OPRP4 control); the caps are disinfected with chlorine water after being received by A6.

[0057] Production Line 2: Primary purified water undergoes deep sterilization via the B21 ozone mixer (CCP1 control), is then filled by the B37 filling machine, and finally capped by the B38 capping machine (OPRP5 control); bottle caps are disinfected with A8 ozone water after being received by A12.

[0058] Production Line 3: After empty barrels are received at A15, they are sequentially processed through B51 film cutting and cap removal, B52 spray rinsing, B55 high-pressure internal washing, B56 alkaline washing, and B57 chemical washing; the primary purified water is deeply sterilized by the ozone mixer at B58 (controlled by CCP1), then filled by the filling machine at B60, and finally capped at B61; the bottle caps are disinfected with chlorine water at A18 after being received at A17.

[0059] S4. Full-process quality control and rejection of non-conforming products

[0060] After being capped, the products are first inspected by a B27 PET visual inspection instrument to check the cap sealing, coding integrity, and liquid level. Non-conforming products are rejected by C1. Conforming products are then inspected by a B29 / B43 / B62 light inspection machine to check the water cleanliness, followed by a B30 label visual inspection instrument to check the label adhesion, and a B32 weighing instrument to check the packaging weight. Subsequent non-conforming products are all rejected by C1.

[0061] S5. Packaging, Warehousing, and Waste Disposal

[0062] Finally, qualified products are labeled by B28 / B41 and fitted with handles by B42. They are then packaged by B31 / B47 packaging machines, and production information is marked by B33 / B48 / B65 inkjet printing. Finally, they are palletized by B34 / B49 palletizing machines and stored in the storage equipment. Waste empty bottles, waste bottle caps, waste labels, etc. are collected in C2 through a special channel, and after being crushed or compressed, they are disposed of through C3 for takeaway.

[0063] The above embodiments are only used to illustrate specific implementations of the present invention and are not limited thereto. For those skilled in the art, various similar modifications and transformations can be made based on the concept of the present invention, and these modifications and transformations should all be considered within the scope of protection of the present invention.

Claims

1. A multi-stage progressive sterilization process for mineral water, characterized in that, Includes the following steps: S1. Raw water pretreatment: After obtaining groundwater, it is sequentially aerated, filtered by manganese sand and then filtered by quartz sand, and then cooled to room temperature by a plate exchanger. S2. Multi-stage filtration and preliminary sterilization: The pretreated raw water is filtered through fine filtration and ultrafiltration membranes in sequence, and then sterilized by UV lamps to obtain primary purified water; S3. Deep sterilization and filling by separate production lines: The primary purified water is transported to three production lines. Line 1 is suitable for 360ml / 500ml / 1.5L products, Line 2 is suitable for 4.5L / 15L products, and Line 3 is suitable for 17.9L bottled water. Each line is deeply sterilized by an ozone mixing unit, and then filling and capping are completed accordingly. S4. Full-process quality control: Defective products are removed through PET visual inspection, light inspection, and label visual inspection. Qualified products are packaged, inkjet-printed, and palletized before being put into storage. S5. Waste sorting and processing: Collect discarded empty bottles, bottle caps, labels, cardboard boxes, and films separately, store them temporarily, and then sell them off-site.

2. The multi-stage progressive sterilization process for mineral water as described in claim 1, characterized in that, The UV lamp sterilization described in S2 uses a dual UV lamp series configuration.

3. The multi-stage progressive sterilization process for mineral water as described in claim 1, characterized in that, The ozone concentration of the ozone mixing unit described in S3 is adjusted to match the product capacity of the corresponding production line.

4. The multi-stage progressive sterilization process for mineral water as described in claim 1, characterized in that, The manganese sand filtration and quartz sand filtration described in S1 use graded filter media to achieve step-by-step impurity removal.

5. The multi-stage progressive sterilization process for mineral water as described in claim 1, characterized in that, As described in S3, laser marking is added after the cap is sealed. The marking information includes key production parameters, and the clarity is verified by visual inspection.

6. The multi-stage progressive sterilization process for mineral water as described in claim 1, characterized in that, The bottle cap disinfection methods for each production line in S3 are differentiated: Line 1 uses chlorine water disinfection, Line 2 uses ozone water disinfection, and Line 3 uses a combination of chlorine water and chlorine dioxide disinfection.

7. The multi-stage progressive sterilization process for mineral water as described in claim 1, characterized in that, The quality control described in S4 also includes weighing and testing of bags and packages, and rejecting packages that exceed the preset error range as unqualified products.

8. The multi-stage progressive sterilization process for mineral water as described in claim 1, characterized in that, The waste products described in S5 are collected through a dedicated channel, empty bottles are crushed, and waste labels and waste films are compressed, packaged, and sold.

9. A multi-stage progressive sterilization device for mineral water based on the process described in any one of claims 1-8, characterized in that, include: Raw water pretreatment unit: connected in sequence to an aeration device, a manganese sand filter, a quartz sand filter, a plate exchanger, and a raw water tank; Multi-stage purification and sterilization unit: sequentially connected fine filter, ultrafiltration membrane module, dual UV lamp sterilization device and purified water tank; Production lines: Lines 1, 2 and 3 are respectively equipped with ozone mixers, filling machines and capping machines. Line 3 is additionally equipped with a film cutting and capping integrated machine, a spraying device and a high-pressure internal washing machine. Quality control unit: includes PET visual inspection instrument, light inspection machine, label visual inspection instrument, weighing sensor and non-conforming product rejection device; Packaging and warehousing unit: sequentially connected labeling machine / sleeve shrink wrapping machine, sleeve handle device, packaging machine, inkjet printer, palletizer and warehousing equipment; Waste processing unit: includes sorting and collection bins, crushing equipment, compression baler and waste temporary storage warehouse.

10. A multi-stage progressive sterilization device for mineral water as described in claim 9, characterized in that, The production line unit and the quality control unit are linked through a PLC control system. When the quality control unit detects a defective product, the PLC controls the key process of the corresponding production line to pause, and resumes operation after the defective product is removed.

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