Aseptic Dosing System for Beverage Changeover
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Solution Overview
Problem
Beverage bottlers face significant downtime and resource consumption when changing over between different beverage products, especially when adding unique additives, due to the need for extensive sanitation and equipment flushing, which discourages production of small volumes and customized products.
Innovation Solution
An aseptic dosing system with multiple micro-ingredient and macro-ingredient sources, a sterilizer with a mesh or other sterilization methods, and a nozzle positioned within a sterile zone, allowing for quick adaptation and continuous production without downtime by ensuring ingredients are sterilized before use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional batch filling process is used with blending tanks and piping, then beverage components can be mixed and filled, but significant downtime occurs during product changeover requiring flushing and sanitation
Solution Approach 1:
The filling system is divided into multiple independent filling heads, each capable of processing different products simultaneously. This segmentation allows the system to switch between products without shutting down the entire line, as each head can be independently configured and operated.
Solution Approach 2:
The filling heads are designed with universal functionality to handle multiple beverage types and formulations. Each head can be quickly reconfigured for different products through programmable controls, eliminating the need for extensive flushing and sanitation during changeovers.
2Reliability
If extensive flushing and sanitation procedures are performed during product changeover, then product purity is maintained, but water and chemical consumption increases significantly
Solution Approach 1:
The system employs disposable sterile barriers and single-use components in the filling heads that can be quickly replaced rather than cleaned. This approach maintains product purity while eliminating the need for extensive water and chemical flushing during changeovers.
Solution Approach 2:
The filling environment is maintained under controlled atmospheric conditions with sterile air filtration and positive pressure systems. This inert environment prevents contamination without requiring aggressive chemical sanitation, reducing water and chemical consumption.
3Productivity
If traditional filling lines are configured for high volume production, then efficiency is improved, but flexibility to produce customized and small volume products decreases
Solution Approach 1:
The filling system incorporates dynamically adjustable parameters including flow rates, filling volumes, and operational sequences that can be modified in real-time through programmable logic controllers. This allows the system to optimize for both high-volume standard products and low-volume customized products without reconfiguring hardware.
Solution Approach 2:
The system utilizes parameter changes in the control system to adapt between different product types. By modifying operational parameters such as filling speed, volume, and sequence through software rather than hardware changes, the system maintains high efficiency while achieving greater versatility.
4Adaptability or versatility
If multiple product changeovers are performed, then product variety is increased, but operational costs increase due to repeated sanitation processes
Solution Approach 1:
The system maintains continuous operation with multiple filling heads working in parallel, allowing product changeovers to occur without stopping production. One head can be reconfigured while others continue producing, ensuring continuous useful action and eliminating the operational costs associated with shutting down for sanitation.
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
Enables high-speed, efficient production of various beverage products with unique additives without downtime, reducing water and chemical usage, and allowing for simultaneous production of multiple flavors, significantly reducing downtime and operational costs.
Implementation Method 1
The sterilizer may include a mesh. The mesh may have openings of less than about 0.45 microns
Implementation Method 2
The sterilizer may include a pasteurizer, a microwave pasteurizer, an electron beam sterilization system, an ultraviolet light system, and a high pressure system.
Implementation Method 3
The sterilizer may include a pasteurizer, a microwave pasteurizer, an electron beam sterilization system, an ultraviolet light system, and a high pressure system.
Implementation Method 4
The sterilizer may include a pasteurizer, a microwave pasteurizer, an electron beam sterilization system, an ultraviolet light system, and a high pressure system.
Data Source
Figure 1
Figure 2~2A
Figure 3~4
AI summary
The present application provides an aseptic dosing system (100) for dispensing a micro- ingredient (135). The aseptic dosing system (100) may include a micro - ingredient source (140) adapted to dispense the micro - ingredient (135), a sterilizer (420) downstream of the micro - ingredient source (140) configured to sterilize the micro - ingredient (135), and a nozzle (140) downstream of the sterilizer (420) configured to reconstitute the micro - ingredient (135) in or downstream thereof.