A filling and sterilizing device for prolonging the shelf life of high foam protein liquid

Abstract

The utility model discloses a kind of filling sterilization devices for improving high bubble protein liquid shelf life, it is related to protein liquid sterilization technical field, including: pretreatment device, multistage sterilization device, sterile filling device, control box, the utility model removes dissolved oxygen by vacuum degassing device, combined with inert gas filling protection, oxygen residual amount is reduced to below 0.5%, effectively inhibits oxidation reaction, makes high bubble protein liquid shelf life extend to 6-12 months, again through high temperature short time sterilization and ultraviolet auxiliary sterilization dual sterilization mode, sterilization rate is ≥99.9%, while through the rapid temperature control of plate heat exchanger, avoid protein denaturation and foam structure damage, again through sterile cabin body cooperation positive pressure air supply and air filter, maintain filling clean environment, the variable frequency peristaltic pump of low shear force filling device and under liquid filling head realize gentle filling.

Description

Technical Field

[0001] This utility model relates to the field of protein liquid sterilization technology, specifically a filling and sterilization device for improving the shelf life of high-foaming protein liquid. Background Technology

[0002] High-foaming protein solutions are widely used in the food and pharmaceutical industries due to their rich nutritional value and unique foaming properties. However, during processing, dissolved oxygen and bubbles in the protein solution can easily trigger oxidation reactions, leading to browning and nutrient loss. Simultaneously, microbial residues, such as heat-resistant spores, can easily multiply during storage, causing spoilage. Traditional vacuum degassing and pasteurization processes have limited oxygen and microbial removal rates, and prolonged high-temperature treatment can cause protein denaturation and decreased foam stability. Existing filling equipment often employs open designs or high-speed filling pumps, which easily introduce environmental microorganisms during the filling process. Furthermore, high shear forces can damage the protein solution's foam structure, leading to stratification or foam collapse. In addition, traditional equipment often operates with independent units such as degassing, filtration, and sterilization, lacking flow and pressure buffering mechanisms, resulting in frequent production interruptions and high energy consumption. Therefore, there is an urgent need for a filling and sterilization device that integrates efficient deoxygenation, multi-stage synergistic sterilization, aseptic low-loss filling, and intelligent control to solve the problems of oxidative spoilage, microbial residues, quality damage, and production discontinuity in the processing of high-foaming protein solutions. Utility Model Content

[0003] The purpose of this invention is to provide a filling and sterilization device that extends the shelf life of high-foaming protein liquid, thereby solving the problems mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a filling and sterilization device for improving the shelf life of high-foaming protein liquid, comprising: a pretreatment device, a multi-stage sterilization device, an aseptic filling device, and a control box connected sequentially along the material flow direction; the pretreatment device includes a vacuum degassing device, a precision filtration device connected below the vacuum degassing device, the precision filtration device being connected to the multi-stage sterilization device via a delivery pump; the multi-stage sterilization device includes a high-temperature short-time sterilization device connected to the precision filtration device via a pipeline; the end of the high-temperature short-time sterilization device is connected to an ultraviolet-assisted sterilization device, the end of the ultraviolet-assisted sterilization device being connected to the aseptic filling device; the aseptic filling device includes an aseptic chamber, the top of the aseptic chamber being equipped with an air filter, a positive pressure blower, and an inert gas device; a low-shear filling device is installed inside the aseptic chamber; and the control box contains a control system electrically connected to the pretreatment device, the multi-stage sterilization device, and the aseptic filling device.

[0005] Furthermore, the vacuum degassing device includes: a degassing tank, a vacuum pump and an exhaust valve at the top of the degassing tank, a liquid level sensor inside the degassing tank, and a precision filter connected to the bottom of the degassing tank.

[0006] Furthermore, the precision filtration device includes a coarse filter tank, a fine filter tank, and a buffer tank connected in series. The inlet of the coarse filter tank is connected to the outlet of the degassing tank, the outlet of the fine filter tank is connected to the buffer tank, and the outlet of the buffer tank is connected to a multi-stage sterilization device via a transfer pump.

[0007] Furthermore, the high-temperature short-time sterilization device includes: a plate heat exchanger, which includes a preheating section, a sterilization section and a cooling section. The inlet of the preheating section is connected to a buffer tank. A temperature sensor is installed inside the sterilization section. A circulating cooling pipe is installed outside the cooling section. The outlet of the cooling section is connected to an ultraviolet-assisted sterilization device through a stainless steel pipe.

[0008] Furthermore, the ultraviolet-assisted sterilization device includes a laminar flow distributor, which includes an ultraviolet lamp and a quartz sleeve. The inlet of the laminar flow distributor is connected to the outlet of a cooling section via a stainless steel pipe, and the outlet of the laminar flow distributor is connected to an aseptic filling device via a delivery pump.

[0009] Furthermore, the low shear force filling device includes: a storage bin, the inlet of which is connected to the outlet of a laminar flow distributor, a variable frequency peristaltic pump at the bottom of the storage bin, a submersible filling head at the bottom of the variable frequency peristaltic pump connected to the submersible filling head via a hose, the submersible filling head being connected to the side wall of the sterile chamber via a lifting bracket, and a lifting motor connected to the lifting bracket on the side of the sterile chamber.

[0010] Furthermore, the inert gas device includes: an inert gas tank at the top of the sterile chamber, an inert gas pipe at the bottom of the inert gas tank penetrating the sterile chamber, an inert gas nozzle connected to the end of the inert gas pipe, and the inert gas nozzle located on the side of the submersible filling head.

[0011] Compared with existing technologies, the beneficial effects of this utility model are as follows: This utility model removes dissolved oxygen through a vacuum degassing device, combined with inert gas filling protection, reducing the residual oxygen content to below 0.5%, effectively inhibiting oxidation reactions and extending the shelf life of high-foaming protein liquid to 6-12 months. Furthermore, through a dual sterilization method of high-temperature short-time sterilization and ultraviolet-assisted sterilization, the sterilization rate is ≥99.9%. Simultaneously, rapid temperature control via a plate heat exchanger prevents protein denaturation and foam structure damage. A sterile chamber, combined with positive pressure air supply and an air filter, maintains a clean filling environment. The variable frequency peristaltic pump and submersible filling head of the low-shear filling device achieve gentle filling. Finally, the control box monitors and adjusts parameters such as degassing liquid level, sterilization temperature, and filling speed in real time, ensuring continuous operation throughout the entire process, reducing manual intervention, and improving production efficiency. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of this utility model;

[0013] Figure 2 This is a schematic diagram of the pretreatment device of this utility model;

[0014] Figure 3 This is a schematic diagram of the multi-stage sterilization device of this utility model;

[0015] Figure 4 This is a schematic diagram of the laminar flow distributor of this utility model;

[0016] Figure 5 This is a schematic diagram of the plate heat exchanger structure of this utility model;

[0017] Figure 6 This is a schematic diagram of the aseptic filling device of this utility model;

[0018] Figure 7 This is a schematic diagram of the low shear force filling device of this utility model;

[0019] In the diagram: 1. Pretreatment unit; 2. Multi-stage sterilization unit; 3. Aseptic filling unit; 4. Control box; 101. Degassing tank; 102. Vacuum pump; 103. Exhaust valve; 104. Liquid level sensor; 105. Coarse filter tank; 106. Fine filter tank; 107. Buffer tank; 201. Plate heat exchanger; 2011. Preheating section; 2012. Sterilization section; 2013. Cooling section; 202. Temperature sensor; 203. Circulating cooling pipe; 204. Laminar flow distributor. 2041. Ultraviolet lamp tube; 2042. Quartz sleeve; 301. Sterile chamber; 302. Air filter; 303. Positive pressure blower; 304. Inert gas device; 3041. Inert gas tank; 3042. Inert gas pipeline; 3043. Inert gas nozzle; 305. Low shear force filling device; 3051. Storage silo; 3052. Variable frequency peristaltic pump; 3053. Submersible filling head; 3054. Lifting support; 3055. Lifting motor. Detailed Implementation

[0020] To enable those skilled in the art to better understand the technical solutions of this utility model, the technical solutions in the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings and specific embodiments.

[0021] Please refer to Figure 1-7This utility model provides a filling and sterilization device for improving the shelf life of high-foaming protein liquid, comprising: a pretreatment device 1, a multi-stage sterilization device 2, an aseptic filling device 3, and a control box 4 connected sequentially along the material flow direction. The pretreatment device 1 includes a vacuum degassing device, and a precision filtration device is connected below the vacuum degassing device. The precision filtration device is connected to the multi-stage sterilization device 2 via a delivery pump. The multi-stage sterilization device 2 includes a high-temperature short-time sterilization device connected to the precision filtration device via a pipeline. An ultraviolet-assisted sterilization device is connected to the end of the high-temperature short-time sterilization device. The end of the ultraviolet-assisted sterilization device is connected to the aseptic filling device 3. The aseptic filling device 3 includes an aseptic chamber 301. An air filter 302, a positive pressure blower 303, and an inert gas device 304 are provided on the top of the aseptic chamber 301. A low-shear filling device 305 is provided inside the aseptic chamber 301. The control box 4 contains a control system that is electrically connected to the pretreatment device 1, the multi-stage sterilization device 2, and the aseptic filling device 3.

[0022] The system includes a vacuum degassing device that removes dissolved oxygen and air bubbles from the liquid through vacuuming, reducing oxidation and extending shelf life. A precision filtration device sequentially filters large particles and microorganisms, ensuring material cleanliness and preventing clogging or contamination of subsequent equipment. A high-temperature short-time sterilization device, using a plate heat exchanger (e.g., HTST), rapidly heats and sterilizes, killing most microorganisms while preserving the protein solution's nutrients. An ultraviolet-assisted sterilization device uses ultraviolet light to destroy microbial DNA, supplementing the limitations of high-temperature sterilization, especially effective against heat-resistant bacteria. A sterile chamber 301 provides a closed, sterile environment to prevent secondary contamination. An air filter 302 and a positive pressure blower 303 continuously supply sterile air and maintain positive pressure, preventing external microorganisms from entering. An inert gas device 304 injects inert gases such as nitrogen to replace residual oxygen and inhibit oxidation. A low-shear filling device 305 uses a peristaltic pump and a submersible filling head for slow filling, avoiding damage to the foam structure of the high-foaming protein solution. The control box 4 integrates sensors and an automation system to monitor parameters such as degassing liquid level, sterilization temperature, and filling speed in real time, ensuring stable operation throughout the entire process.

[0023] The vacuum degassing device includes: a degassing tank 101, a vacuum pump 102 and an exhaust valve 103 on the top of the degassing tank 101, a liquid level sensor 104 inside the degassing tank 101, and the bottom of the degassing tank 101 is connected to a precision filter device.

[0024] The degassing tank 101 contains the material and is evacuated by a vacuum pump 102 to create a negative pressure environment, promoting the release of dissolved oxygen. The vacuum pump 102 and the exhaust valve 103 work together to control the pressure inside the tank. The exhaust valve regulates the vacuum level to prevent excessive degassing that could lead to liquid boiling. A level sensor 104 monitors the liquid level in real time to prevent overflow or dry running of the degassing tank, ensuring continuous production. Through pressure and level linkage control, oxygen is efficiently removed without damaging the material.

[0025] The precision filtration device includes a coarse filter tank 105, a fine filter tank 106 and a buffer tank 107 connected in series. The inlet of the coarse filter tank 105 is connected to the outlet of the degassing tank 101. The outlet of the fine filter tank 106 is connected to the buffer tank 107. The outlet of the buffer tank 107 is connected to the multi-stage sterilization device 2 through a transfer pump.

[0026] The coarse filter 105 uses a large-pore filter screen to intercept suspended particles, protecting the subsequent fine filter. The fine filter 106 uses a microfiltration membrane to retain microorganisms and tiny impurities, achieving aseptic filtration. The buffer tank 107 temporarily stores the filtered liquid, balancing flow fluctuations and ensuring continuous feeding in the sterilization section. The coarse filter protects the fine filter and extends the filter cartridge life; the buffer tank stabilizes the flow rate and improves system efficiency.

[0027] The high-temperature short-time sterilization device includes a plate heat exchanger 201, which includes a preheating section 2011, a sterilization section 2012, and a cooling section 2013. The inlet of the preheating section 2011 is connected to the buffer tank 107. The sterilization section 2012 is equipped with a temperature sensor 202. The cooling section 2013 is equipped with a circulating cooling pipe 203. The outlet of the cooling section 2013 is connected to the ultraviolet-assisted sterilization device through a stainless steel pipe.

[0028] The preheating section 2011 utilizes the residual heat of the sterilized material to preheat the newly arrived liquid, saving energy and reducing consumption. The sterilization section 2012 uses high-temperature steam for rapid sterilization, and the temperature sensor 202 ensures accurate sterilization temperature. The cooling section 2013 uses circulating cooling water to rapidly cool the material to the filling temperature, preventing protein denaturation. The circulating cooling pipe 203 accelerates cooling to prevent the material from overheating and affecting quality.

[0029] The ultraviolet-assisted sterilization device includes a laminar flow distributor 204, which includes an ultraviolet lamp tube 2041 and a quartz sleeve 2042. The inlet of the laminar flow distributor 204 is connected to the outlet of a cooling section 2013 via a stainless steel pipe, and the outlet of the laminar flow distributor 204 is connected to an aseptic filling device 3 via a delivery pump.

[0030] The laminar flow distributor 204 enables the liquid to form a thin, uniform flow, ensuring sufficient ultraviolet irradiation. The ultraviolet lamp 2041 and the quartz sleeve 2042 emit ultraviolet light. The quartz sleeve has high light transmittance and is corrosion resistant, directly killing residual microorganisms. The laminar flow distribution and ultraviolet penetration compensate for the blind spots of high-temperature sterilization and improve the sterilization rate.

[0031] The low shear force filling device 305 includes: a storage bin 3051, the inlet of which is connected to the outlet of a laminar flow distributor 204, a variable frequency peristaltic pump 3052 at the bottom of the storage bin 3051, a submersible filling head 3053 at the bottom of the variable frequency peristaltic pump 3052 via a hose, the submersible filling head 3053 being connected to the side wall of a sterile chamber 301 via a lifting bracket 3054, and a lifting motor 3055 connected to the lifting bracket 3054 on the side of the sterile chamber 301.

[0032] The storage bin 3051 temporarily stores the sterilized liquid and buffers the filling pressure. The variable frequency peristaltic pump 3052 controls the filling speed by adjusting the rotation speed to avoid shearing force generated by high-speed flow. The submersible filling head 3053 and the lifting bracket 3054 immerse the filling head below the liquid surface of the container and adjust the height with the lifting motor 3055 to prevent foam from bursting.

[0033] The inert gas device 304 includes: an inert gas tank 3041 at the top of a sterile chamber 301, an inert gas pipe 3042 at the bottom of the inert gas tank 3041 that runs through the sterile chamber 301, an inert gas nozzle 3043 connected to the end of the inert gas pipe 3042, and the inert gas nozzle 3043 located on the side of the submersible filling head 3053.

[0034] The inert gas tank 3041 and pipeline 3042 store and transport inert gas. When the container is filled to 90% to 95% capacity, the inert gas nozzle 3043 injects inert gas into the top of the container to replace the residual oxygen.

[0035] When using this invention, the material first enters the degassing tank 101 of the pretreatment device. A vacuum pump 102 at the top draws a vacuum, removing dissolved oxygen and air bubbles from the liquid to reduce the risk of oxidation. A liquid level sensor 104 inside the degassing tank monitors the liquid level in real time and transmits the data to the control box 4. The control system automatically adjusts according to a preset threshold to ensure that the degassing tank does not overflow and damage the vacuum pump or contaminate the pipes due to excessively high liquid levels, nor does it run dry and damage the pump or affect the degassing effect due to excessively low liquid levels. The degassed liquid then passes through a coarse filter tank 105 to remove large particulate impurities, and a fine filter tank 106 to finely filter microorganisms and tiny particles. Finally, it enters a buffer tank 107 for temporary storage. The buffer tank, acting as an intermediate storage container, temporarily stores the filtered liquid, ensuring continuous supply for subsequent sterilization and filling processes and preventing production interruptions due to flow fluctuations. The buffer tank is then transported to the sterilization device by a transfer pump. The liquid enters the plate heat exchanger 201 and is processed in three stages: the preheating section 2011 uses waste heat to preheat the material, the sterilization section 2012 kills microorganisms instantly at high temperature, the temperature sensor 202 monitors the temperature in real time and feeds the data back to the control box 4. If the temperature is lower than the set value, the control box 4 automatically increases the opening of the steam valve to inject more high-temperature steam into the sterilization section 2012 to raise the material temperature, while reducing the speed of the conveying pump to extend the residence time of the material in the sterilization section. If the temperature is higher than the set value, the steam supply is reduced and the circulating cooling pipe 203 of the cooling section 2013 is started to accelerate the cooling, increase the speed of the conveying pump, shorten the heating time of the material, and avoid overheating that could lead to protein denaturation. The circulating cooling pipe 203 of the cooling section 2013 cools down quickly to avoid overheating that could affect the quality of the protein liquid. After cooling, the liquid enters the laminar flow distributor 204. The ultraviolet lamp 2041 performs secondary sterilization on the material through the quartz sleeve 2042, further reducing microbial residue. The sterile chamber 301 continuously supplies sterile air through the top air filter 302 and the positive pressure blower 303 to form a positive pressure environment and prevent external contamination. The sterilized liquid enters the storage bin 3051 and is transported to the submersible filling head 3053 through the variable frequency peristaltic pump 3052 and hose. The height of the submersible filling head 3053 is controlled by the lifting bracket 3054, which keeps it submerged below the liquid surface to avoid liquid splashing and reduce the damage of shear force to the structure of the high-foaming protein liquid. When the volume is filled to 90% to 95%, the inert gas device 304 injects inert gas into the top of the container to replace the residual oxygen. The control box 4 integrates an automation system to monitor and adjust the parameters of each device in real time, ensuring efficient and stable operation of the entire process and ultimately achieving the goal of extending the shelf life of the high-foaming protein liquid.

[0036] Although embodiments of the present invention have been shown and described, it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, it will be understood by those skilled in the art that all other embodiments obtained by making various changes, modifications, substitutions and alterations to these embodiments without departing from the principles and spirit of the present invention and without creative effort are within the scope of protection of the present invention.

Claims

1. A filling and sterilization device for extending the shelf life of high-foaming protein liquid, characterized in that, include: A pretreatment device (1), a multi-stage sterilization device (2), an aseptic filling device (3), and a control box (4) are connected sequentially along the material flow direction. The pretreatment device (1) includes a vacuum degassing device, and a precision filtration device is connected below the vacuum degassing device. The precision filtration device is connected to the multi-stage sterilization device (2) via a transfer pump. The multi-stage sterilization device (2) includes a high-temperature short-time sterilization device connected to the precision filtration device via a pipeline. An ultraviolet-assisted sterilization device is connected to the end of the high-temperature short-time sterilization device. The end of the ultraviolet-assisted sterilization device is connected to the aseptic filling device (3). The aseptic filling device (3) includes an aseptic chamber (301). The top of the aseptic chamber (301) is provided with an air filter (302), a positive pressure blower (303), and an inert gas device (304). The interior of the aseptic chamber (301) is provided with a low shear force filling device (305). The control box (4) is provided with a control system that is electrically connected to the pretreatment device (1), the multi-stage sterilization device (2), and the aseptic filling device (3).

2. The filling and sterilization device for extending the shelf life of high-foaming protein liquid according to claim 1, characterized in that, The vacuum degassing device includes: a degassing tank (101), a vacuum pump (102) and an exhaust valve (103) on the top of the degassing tank (101), a liquid level sensor (104) inside the degassing tank (101), and the bottom of the degassing tank (101) is connected to a precision filter device.

3. The filling and sterilization device for extending the shelf life of high-foaming protein liquid according to claim 2, characterized in that, The precision filtration device includes a coarse filter tank (105), a fine filter tank (106), and a buffer tank (107) connected in series. The inlet of the coarse filter tank (105) is connected to the outlet of the degassing tank (101), and the outlet of the fine filter tank (106) is connected to the buffer tank (107). The outlet of the buffer tank (107) is connected to the multi-stage sterilization device (2) through a transfer pump.

4. The filling and sterilization device for extending the shelf life of high-foaming protein liquid according to claim 3, characterized in that, The high-temperature short-time sterilization device includes a plate heat exchanger (201), which includes a preheating section (2011), a sterilization section (2012), and a cooling section (2013). The inlet of the preheating section (2011) is connected to a buffer tank (107). A temperature sensor (202) is installed inside the sterilization section (2012). A circulating cooling pipe (203) is installed outside the cooling section (2013). The outlet of the cooling section (2013) is connected to an ultraviolet-assisted sterilization device through a stainless steel pipe.

5. The filling and sterilization device for extending the shelf life of high-foaming protein liquid according to claim 4, characterized in that, The ultraviolet-assisted sterilization device includes a laminar flow distributor (204), which includes an ultraviolet lamp tube (2041) and a quartz sleeve (2042). The inlet of the laminar flow distributor (204) is connected to the outlet of a cooling section (2013) through a stainless steel pipe, and the outlet of the laminar flow distributor (204) is connected to an aseptic filling device (3) through a delivery pump.

6. The filling and sterilization device for extending the shelf life of high-foaming protein liquid according to claim 5, characterized in that, The low shear force filling device (305) includes: a storage bin (3051), the inlet of which is connected to the outlet of a laminar flow distributor (204), a variable frequency peristaltic pump (3052) at the bottom of the storage bin (3051), a submersible filling head (3053) at the bottom of the variable frequency peristaltic pump (3052) via a hose, the submersible filling head (3053) being connected to the side wall of a sterile chamber (301) via a lifting bracket (3054), and a lifting motor (3055) connected to the lifting bracket (3054) on the side of the sterile chamber (301).

7. The filling and sterilization device for extending the shelf life of high-foaming protein liquid according to claim 6, characterized in that, The inert gas device (304) includes: an inert gas tank (3041) at the top of the sterile chamber (301), an inert gas pipe (3042) at the bottom of the inert gas tank (3041) passing through the sterile chamber (301), an inert gas nozzle (3043) connected to the end of the inert gas pipe (3042), and the inert gas nozzle (3043) located on the side of the submersible filling head (3053).

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