Aseptic Bottle Molding Temperature Control for Reliable Sterilization
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Solution Overview
Problem
Conventional aseptic filling machines risk inadequate sterilization of bottles with insufficient heating, leading to potential molding failures and excessive use of sterilizers, as the mold temperature control is inadequate during the initial stages of bottle molding.
Innovation Solution
The aseptic filling method and machine control the mold temperature using a mold temperature adjusting apparatus to maintain the surface temperature of molded bottles within a specified range by adjusting the temperature of the neck, body, and bottom portion molds, ensuring adequate sterilization with a reduced amount of sterilizer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mold temperature is not controlled during initial bottle molding, then the molding process can be simplified, but the surface temperature of bottles becomes insufficient for adequate sterilization
Solution Approach 1:
The mold temperature is adjusted in advance before bottle molding to ensure that the surface temperature of molded bottles reaches the required level for adequate sterilization. This preliminary temperature adjustment prevents insufficient heating during the molding process itself.
Solution Approach 2:
The mold temperature is controlled based on feedback from temperature measurements of the molded bottles. By measuring the surface temperature of bottles and adjusting the mold temperature accordingly, the system ensures consistent and adequate sterilization conditions.
2Reliability
If all molded bottles are fed to sterilization regardless of temperature, then the sterilization process can be simplified, but faulty bottles with insufficient heating may be filled and shipped
Solution Approach 1:
The mechanical/conventional approach of filtering bottles by temperature is replaced with an infrared measurement system that non-contactly measures surface temperature of bottles to identify those requiring sterilization.
Solution Approach 2:
The system changes the parameter of bottle surface temperature through controlled mold temperature adjustment, ensuring that bottles reach the required temperature threshold before sterilization, thereby eliminating the need for complex temperature-based filtering.
3Reliability
If excessive sterilizer is used to ensure adequate sterilization of all bottles, then sterilization reliability improves, but waste and cost increase
Solution Approach 1:
The temperature parameter of the mold is precisely controlled to ensure bottles reach the optimal temperature for sterilization. This parameter control allows adequate sterilization with reduced sterilizer用量, minimizing waste while maintaining effectiveness.
Solution Approach 2:
The bottles themselves serve the function of temperature regulation through controlled mold heating, ensuring they reach the required temperature for sterilization without requiring external temperature intervention during the sterilization process.
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
This approach ensures reliable sterilization of bottles with controlled surface temperatures, reducing waste and maintaining consistent bottle quality by minimizing excess sterilizer use and preventing molding defects.
Implementation Method 1
a heating apparatus that heats the preform to a temperature for molding the preform into a bottle
Implementation Method 2
a blow-molding apparatus that blow-molds the heated preform into a bottle
Implementation Method 3
control the temperature of the mold that molds the bottle... adjusting the temperature of the neck, body, and bottom portion molds
Implementation Method 4
a sterilizing portion that sterilizes the bottle molded by the molding portion with a sterilizer... the heat applied to the bottle in the molding phase can be used to increase the sterilization effect of a mist of hydrogen peroxide
Data Source
Figure 1
Figure 2(A)~2(D)
Figure 3(E-1)~3(H)
AI summary
Even when the filling speed increases, the surface temperature of a molded bottle falls within a constant range, and a sterilizer adequately sterilizes the bottle. A preform is heated, the heated preform is sealed in a mold, the preform sealed in the mold is blow-molded into a bottle, the surface temperatures of a neck portion, a body portion, and a bottom portion of the molded bottle are measured, and the mold temperatures of a neck portion, a body portion, and a bottom portion of the mold is so adjusted that the measured surface temperature of the bottle falls within a specified temperature range.