Aseptic Filling Machine Airflow System Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Maintaining uniform and aseptic airflow in paperboard container filling machines is challenging due to moving parts and container transport, which can lead to contamination from non-sterile air entering the aseptic chambers.
Innovation Solution
The implementation of an airflow system featuring an upper air distribution chamber, a lower processing chamber, and a throughflow plate with slits aligned parallel to the container transport path, along with an elongated air distribution duct, ensures a controlled and uniform flow of clean air through the aseptic chambers, minimizing turbulence and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If containers are transported through the aseptic chamber and processing equipment operates, then filling and sealing operations can be performed, but turbulence is generated and contaminated air can seep into the aseptic chamber
Solution Approach 1:
The airflow system is segmented into multiple functional zones: a first airflow system provides clean air to the filling chamber while a second airflow system provides clean air to the sealing chamber. The airflow is further segmented through multiple inlets and distribution chambers, allowing independent control of sterile airflow in different operational zones, thereby maintaining aseptic conditions despite container transport and processing operations.
Solution Approach 2:
Clean air acts as an intermediary substance that displaces and prevents contaminated air from entering the aseptic chamber. The system introduces controlled streams of sterile air through distribution plates and chambers, creating a protective airflow barrier that envelops containers during transport and processing, thereby preventing contamination without stopping productivity.
2Object-affected harmful factors
If the aseptic chamber is kept airtight, then contamination is prevented, but containers cannot be transported in and out and processing equipment cannot operate
Solution Approach 1:
The system implements local quality by providing different airflow characteristics to different locations within the aseptic chamber. Clean air is directed specifically at container surfaces and critical processing zones through targeted inlets and distribution plates, creating localized sterile zones that maintain protection even where the chamber structure must open for container transport and equipment operation.
Solution Approach 2:
Clean air is introduced into the aseptic chamber before containers enter and before processing operations begin. The system pre-establishes a positive pressure environment and directs airflow patterns that will protect containers throughout their entire journey through the chamber, ensuring contamination prevention is already in place before any potential contamination risk arises from chamber openings or equipment operation.
3Object-affected harmful factors
If airflow is increased to prevent contamination, then sterile environment is maintained, but turbulence increases and can cause contamination
Solution Approach 1:
The airflow system is designed to be dynamic, with adjustable airflow rates and patterns that adapt to different operational conditions. The system can modulate the velocity and distribution of clean air to maintain protective levels without creating excessive turbulence, allowing optimization of the balance between contamination prevention and airflow stability based on real-time operational needs.
Solution Approach 2:
The system addresses airflow challenges by introducing control in multiple dimensions: vertical airflow components to counteract turbulence from horizontal container movement, multi-level distribution plates at different heights, and three-dimensional positioning of inlets and outlets. This multi-dimensional approach creates stable sterile zones that remain effective despite the dynamic one-dimensional transport of containers through the chamber.
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 configuration maintains the sterile environment by providing a stable and uniform airflow that envelops containers, preventing the entry of contaminated air and ensuring the quality and shelf-life of filled containers.
Implementation Method 1
The throughflow plate comprises a substantially horizontal planar section and first and second curved sections, each curved section displaying a convex ruled surface facing the processing chamber, the ruled surface being defined by rulings which are parallel and extend orthogonal or substantially orthogonal to said transport path
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A paperboard container filling machine (10) comprising an aseptic chamber (40) having: an upper air distribution chamber (45); a lower processing chamber (46) housing processing equipment (42, 49) configured for interacting with paperboard containers passing through the processing chamber; a throughflow plate (47) separating the air distribution chamber and the processing chamber, the throughflow plate having a plurality of through-openings (48) configured for directing the air from the air distribution chamber to the processing chamber, and a paperboard container transport sub-system configured for transporting the paperboard containers through the processing chamber along a container transport path (14) from an inlet opening (41) to an outlet opening (43) of the processing chamber. The throughflow plate comprising a substantially horizontal planar section (55) and first and second curved sections (56), each curved section displaying a convex ruled surface facing the processing chamber, the ruled surface being defined by rulings which are parallel and extend orthogonal or substantially orthogonal to said transport path.