Aseptic Cap Production and Transport via Sterilizing Gas Tunnel
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Solution Overview
Problem
Current methods for capping containers in aseptic bottling plants are complex and resource-intensive, with caps often becoming contaminated during storage and transportation, requiring additional sterilization and sorting processes that can introduce foreign particles into the bottling process.
Innovation Solution
A device and method where container caps are produced from a hot melt in a cap production device outside the isolator, then transported through a sterilizing gas tunnel into the isolator, ensuring they remain sterile and aligned for direct application, eliminating the need for separate sterilization and sorting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If caps are stored and transported as bulk goods in transport containers, then caps can be produced in advance and stored, but caps become contaminated with microbiological germs and require additional sterilization processes
Solution Approach 1:
The cap production device produces caps directly in the required individual form and transports them immediately to the capping position, eliminating the preliminary bulk storage and subsequent singularization steps. This preliminary individual production and direct transport prevents contamination while maintaining efficient timing.
Solution Approach 2:
The invention extracts the cap production process from the traditional bulk storage and singularization workflow. By producing caps individually and transporting them directly through a controlled tunnel system, the contamination risk associated with bulk storage is eliminated while maintaining production efficiency.
2Reliability
If separate sterilization and sorting systems are added to maintain cap sterility, then cap contamination is reduced, but machine complexity and energy consumption increase
Solution Approach 1:
The invention merges the cap production, transport, and sterilization functions into a single integrated cap production device with an enclosed tunnel system. This combination eliminates the need for separate sterilization and sorting systems, reducing overall machine complexity while maintaining cap sterility through the controlled transport environment.
3Device complexity
If caps are produced individually and transported directly from production to capping, then machine complexity is reduced and cap sterility is maintained, but precise synchronization of production and capping rates is required
Solution Approach 1:
The invention implements feedback control where the cap production device receives signals from the capping machine about required cap rates and timing. This feedback mechanism automatically synchronizes production output with capping demand, enabling precise coordination without complex manual control systems.
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 reduces machine complexity, saves energy and resources, and maintains cap sterility from production to application, preventing contamination and ensuring aseptic conditions without additional sterilization steps.
Implementation Method 1
producing container caps from a hot melt
Implementation Method 2
producing container caps from a hot melt, for example a plastics melt
Implementation Method 3
transported through a sterilizing gas tunnel into the isolator
Data Source
AI summary
A device for capping a container with a container cap, for example in a beverage filling plant, includes an isolator for providing a defined atmosphere in the interior thereof; a capper for capping a container with a container cap, which capper is arranged in the isolator; and a cap production device for producing container caps from a hot melt, for example a plastics melt. The cap production device is arranged outside the isolator, and is interconnected with the isolator or is connected to the isolator via a cap transport tunnel in order to feed produced container caps to the capper.