Aseptic Extruder Filling With Thermal Conduit Sterilization

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Solution Overview

Problem

Existing methods for distributing processed foods produced by extrusion cooking result in flavor loss due to excessive thermal history, which is addressed by implementing an aseptic filling system that reduces thermal exposure and maintains food quality.

Innovation Solution

An aseptic filling system with a temperature-controlled thermal conduit connected to the extruder discharge port ensures sufficient sterilization of processed food through controlled residence time and temperature, combined with packaging in an oxygen-free environment to inhibit microbial growth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If processed food is sterilized by heating under pressure in a sealed container (retort method), then sterilization reliability is improved, but thermal history increases causing flavor loss

Engineering Contradiction:

Improvesterilization reliabilityVSAvoidflavor loss due to thermal history

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The system performs preliminary sterilization in the extruder before filling, achieving sufficient microbial kill at lower temperatures and shorter times. This preliminary action eliminates the need for subsequent high-temperature retort sterilization, thereby preserving flavor while ensuring sterilization reliability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention extracts the sterilization function from the final packaging stage (retort) and moves it to the processing stage (extruder). By taking out the sterilization step from the sealed container heating process and performing it earlier in the extruder with controlled parameters, the system avoids excessive thermal history while maintaining sterilization effectiveness

Inventive Principle:

Principle #2Taking out (Extraction)

2Stability of the object's composition

If processed food is dried before distribution, then storage stability is improved, but additional thermal history is accumulated

Engineering Contradiction:

Improvestorage stabilityVSAvoidthermal history accumulation

Core Design Contradiction:

Stability of the object's compositionVSObject-generated harmful factors

Solution Approach 1:

The system changes the water activity parameter of the processed food during extrusion to achieve stable storage without drying. By controlling moisture content and water activity to appropriate levels during the extrusion process, the food attains sufficient storage stability without requiring additional drying treatments that would accumulate more thermal history

Inventive Principle:

Principle #35Parameter changes

3Reliability

If residence time in thermal conduit is increased, then sterilization effectiveness is improved, but energy consumption increases

Engineering Contradiction:

Improvesterilization effectivenessVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The thermal conduit provides continuous sterilization action as food flows through it, maintaining optimal temperature throughout the residence period. This continuous useful action ensures thorough sterilization effectiveness while optimizing energy utilization, avoiding the need for excessive temperature or time that would waste energy

Inventive Principle:

Principle #20Continuity of useful action

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

The system enables distribution of processed foods at normal temperature with reduced thermal history, preserving flavor and preventing mold growth, thus eliminating the need for drying treatments.

Implementation Method 1

a thermal conduit that is capable of being temperature-controlled to a predetermined sterilization temperature is connected to a discharge port of a barrel portion of the extruder, and the processed food is sterilized according to residence time during which the processed food discharged from the extruder flows through the thermal conduit

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

setting an oxygen concentration in the container in which the processed food is filled and packaged to 1% or less

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS20260091902A1Aseptic filling system, and filling and packaging method

Publication Date: 2026.04.02 TOYO SEIKAN KAISHA LTD

AI summary

Provided is an aseptic filing system, in which, in filling and packaging a processed food processed using an extruder in an aseptic environment, a thermal conduit that is capable of being temperature-controlled to a predetermined sterilization temperature is connected to a discharge port of a barrel portion of the extruder, and the processed food is sterilized according to residence time during which the processed food discharged from the extruder flows through the thermal conduit. Also provided is a filling and packaging method, in which a processing condition is adjusted so that water activity of the processed food discharged from the extruder is less than 0.94, the processed food discharged from the extruder is filled and packaged in a sealable container at a temperature of 65 to 99° C., and an oxygen concentration in the container with the processed food filled and packaged is set to 1% or less.