Adaptive Packaging for Food Sterilization Energy Transfer
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Solution Overview
Problem
Current in-container sterilization methods face challenges with extreme processing conditions, limiting packaging material options, leading to over-processing, high costs, and inefficiencies in energy transfer due to thick, rigid containers, which affect product quality and processing times.
Innovation Solution
Adaptive packaging with a flexible design that allows modification of gas pressure and volume, and composition within the package, enabling efficient energy transfer and product mixing, while using recyclable materials and minimizing package failure risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick, rigid containers are used to withstand extreme processing conditions, then package strength is improved, but energy transfer efficiency deteriorates and processing time increases
Solution Approach 1:
The patent employs flexible packaging materials that can deform under pressure rather than requiring thick rigid walls. The flexible package allows thermal energy to transfer more efficiently through thinner material walls, reducing processing time while maintaining structural integrity through flexibility rather than thickness.
Solution Approach 2:
The invention changes the physical parameters of the packaging system by using flexible materials with different mechanical properties than traditional rigid containers. This allows the package to adapt its shape and volume during processing, improving heat transfer efficiency while maintaining sufficient strength through material selection rather than thickness.
2Productivity
If in-container sterilization is used to process large volumes continuously, then productivity is improved, but packaging material options are limited and product quality deteriorates due to over-processing
Solution Approach 1:
The flexible packaging material enables continuous in-container sterilization processing while accommodating a broader range of packaging types beyond traditional rigid containers. The material's flexibility allows it to withstand processing conditions while enabling better adaptability to different product types and volumes.
Solution Approach 2:
The flexible package dynamically adjusts its shape and volume during the sterilization process, allowing optimization of heat transfer pathways. This dynamic adaptation enables continuous processing of large volumes while maintaining product quality by preventing over-processing through better thermal contact between the sterilizing medium and product.
3Reliability
If high temperature and pressure are applied during sterilization, then sterilization effectiveness is improved, but package failure risk increases due to gas expansion and material degradation
Solution Approach 1:
The flexible packaging material can expand and deform to accommodate gas expansion during high-temperature sterilization without rupturing. This flexibility maintains package integrity under extreme conditions while still achieving effective sterilization, unlike rigid packages that are prone to seam rupture and wall weakening.
Solution Approach 2:
The flexible package design anticipates the expansion forces during sterilization by allowing controlled deformation before failure can occur. The material's elastic properties provide a cushioning effect that absorbs the stress of gas expansion and pressure changes, preventing catastrophic package failure.
4Adaptability or versatility
If laminated card or paperboard packaging is used, then packaging versatility is improved, but material integrity deteriorates due to water absorption during processing
Solution Approach 1:
The flexible packaging uses water-resistant film materials that maintain their structural integrity during wet sterilization processes. These films do not absorb water like laminated card or paperboard, preventing softening and loss of strength while still providing versatile packaging options for various products.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces processing times, improves product quality, and lowers costs by optimizing energy usage and packaging material efficiency, allowing for a wide range of products to be processed in a single system without pre-sterilizing containers.
Implementation Method 1
one or more mechanisms, which may be active or passive, to allow controlled and selective movement of gas but not liquid and/or solids within the package and to its outside
Implementation Method 2
improving energy transfer
Implementation Method 3
improving product mixing
Implementation Method 4
the often significant expansion of the package contents, particularly the gas/air in the package headspace
Data Source
AI summary
The present invention relates to a re-closable package, wherein at least one layer of said package is derived and fabricated essentially from a single piece of packaging material, has at least an inner and outer chamber, each capable of holding one or more separate or mixed solid or liquid food components. It also relates to one or more mechanisms within said package design and configuration preferentially allowing controlled movement of gas but not liquid and/or solids both within the package and/or from within the package to the outside. It further relates to a method for controlling and selectively modifying a number of processing conditions within said packaging, particularly pack pressure, gas volume and gas composition. It also relates to package design capability to accelerate and/or optimize product processing within any food sterilization or pasteurization system and its subsequent handling, storage and transportation without further modification.