Aseptic Cup Sterilization and Filling via Inverted Conveyance
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Solution Overview
Problem
Conventional aseptic filling systems face challenges in maintaining stable container conveyance and aseptic conditions, particularly with lightweight containers, as they require multiple chambers and rely on volatile sterilization agents, which limits sterilization efficiency and increases the risk of thermal deformation and odor adhesion. Additionally, these systems struggle to maintain high sterilization levels for both containers and contents, especially for low-acid beverages that require chilled distribution.
Innovation Solution
The method involves conveying cup-shaped containers in an integrated chamber using separate conveyors for sterilization, washing, and filling, with the container initially inverted and then upright, utilizing a peracetic acid solution for sterilization and aseptic water for washing. This setup includes a preliminary pressure zone to control air flow and prevent external air penetration, and partitions to contain sterilization agent droplets and odors, ensuring reliable sterilization and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If containers are conveyed in an upright state through one chamber from sterilization to filling, then the process is simplified, but washing cannot be performed effectively and sterilization agent removal is limited
Solution Approach 1:
The patent inverts the container during the sterilization and washing processes, allowing washing water to flow into and through the container effectively. After washing, the container is inverted again before filling. This inversion strategy resolves the contradiction by enabling thorough washing while maintaining a simplified single-chamber process.
2Reliability
If a sufficient amount of sterilization agent is sprayed for reliable sterilization, then sterilization efficiency improves, but the sterilization agent cannot be completely removed and may adhere to contents
Solution Approach 1:
The patent uses the inversion of the container to convert the potential harm of sterilization agent residue into a benefit. By inverting the container during sterilization and washing, the sterilization agent is more effectively distributed and subsequently removed by washing water, ensuring both reliable sterilization and complete removal of residues.
3Ease of manufacture
If lightweight cup-shaped containers are used, then ease of manufacture and cost improve, but stable conveyance becomes difficult under pressure differences
Solution Approach 1:
The patent maintains the container in an inverted state throughout the sterilization and washing processes, which stabilizes lightweight cup-shaped containers. The inversion prevents the containers from being affected by pressure differences that would cause instability during conveyance, while still allowing effective washing water flow.
4Reliability
If multiple chambers are used for sterilization and filling, then aseptic conditions improve, but device complexity and space requirements increase
Solution Approach 1:
The patent merges the sterilization, washing, and filling processes into a single integrated chamber. By using container inversion and controlled water flow, the system maintains high aseptic conditions while eliminating the need for multiple separate chambers, thus reducing device complexity and space requirements.
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 allows for stable and efficient sterilization and washing of lightweight containers, preventing thermal deformation and odor adhesion, while maintaining high aseptic conditions within the chamber, enabling reliable sterilization and stable conveyance, even for low-acid beverages that can be distributed at normal temperatures.
Implementation Method 1
sterilization is performed by spraying a sterilization agent on at least the inner surface of the container in the inverted state
Implementation Method 2
washing is performed by spraying aseptic water on at least the inner surface of the container in the inverted state
Implementation Method 3
a preliminary pressure zone is provided before the main air discharge port and partitioned by a partition wall from the main chamber of the aseptic chamber, and the flow direction of air inside the chamber is controlled by controlling the pressure
Data Source
AI summary
Cup-shaped containers can be turned over and transferred with good stability from a sterilization-washing zone to the filling-sealing zone inside an aseptic chamber, and admixture of odor or microorganisms is prevented.The first conveyor 2 for conveying the cup-shaped container 38 in an inverted state and a second conveyor 3 for conveying the container in an upright state downstream of the first conveyor 2 are disposed in series in substantially the same plane inside a continuous aseptic chamber 1. A container supply device, a container sterilization device, and a container washing device are disposed successively along the first conveyor 2. A contents filling device 40, a lid material sealing device 41, and a device for discharging the sealed cup-shaped container are installed successively along the second conveyor 3. Sterilization and washing are performed in an inverted state, while conveying the container with the first conveyor 2. The washed container is turned over and transferred from the first conveyor to the second conveyor 3 and the contents filling and lid sealing are performed on the second conveyor.