Aseptic Filling Machine Trouble Recovery via Chamber Segmentation

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Solution Overview

Problem

Aseptic filling machines require extensive cleaning and sterilization of all chambers when a trouble occurs, leading to reduced productivity and energy wastage, as the entire machine needs to be re-sterilized to maintain the aseptic condition upon resuming operation.

Innovation Solution

The method involves maintaining aseptic conditions in all chambers except the one with the trouble, where only the interior of that chamber is made non-aseptic to allow for trouble removal, and then sterilized, allowing for quicker resumption of operation by limiting cleaning and sterilization to the affected area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire aseptic filling machine is cleaned and sterilized when a trouble occurs, then the aseptic condition is maintained, but the downtime increases and productivity decreases

Engineering Contradiction:

Improveaseptic conditionVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent divides the aseptic filling machine into multiple independent chambers (first chamber, second chamber, third chamber) that can be independently sealed and pressurized. When a trouble occurs in one chamber, only that specific chamber needs to be opened for maintenance while other chambers remain sealed and pressurized, allowing the machine to resume operation in those chambers without complete shutdown.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different pressure conditions to different chambers based on their operational status. Chambers that are functioning normally are maintained at positive pressure to preserve aseptic conditions, while the chamber requiring maintenance is isolated. This localized approach allows maintenance in one area without affecting the aseptic status of other areas.

Inventive Principle:

Principle #3Local quality

2Reliability

If all chambers are sterilized when a trouble occurs, then contamination is prevented, but energy consumption increases

Engineering Contradiction:

Improvecontamination preventionVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The sterilization process is segmented to apply only to the specific chamber where contamination risk exists. The positive pressure system allows selective sterilization of individual chambers rather than requiring sterilization of the entire machine, significantly reducing energy consumption while maintaining contamination prevention.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of sterilizing all chambers (excessive action), the system applies sterilization only to the affected chamber (partial action). The positive pressure maintenance in other chambers provides sufficient protection against contamination without the need for redundant sterilization cycles.

Inventive Principle:

Principle #16Partial or excessive action

3Ease of repair

If the aseptic filling machine is shut down completely for maintenance, then the trouble can be removed, but the productivity and recovery speed decrease

Engineering Contradiction:

Improvetrouble removalVSAvoidrecovery speed

Core Design Contradiction:

Ease of repairVSProductivity

Solution Approach 1:

The machine is segmented into independently controllable chambers with separate sealing mechanisms. This allows the affected chamber to be opened for maintenance while other chambers remain operational, enabling trouble removal without complete shutdown and significantly improving recovery speed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent enables continuous operation of unaffected chambers while maintenance is performed on the affected chamber. The positive pressure system maintains aseptic conditions in operational chambers continuously, allowing useful production action to continue uninterrupted in those sections while repair occurs elsewhere.

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

This approach reduces downtime and energy consumption by isolating the non-aseptic chamber, enabling faster recovery and maintaining aseptic conditions in other parts of the machine, thus improving productivity.

Implementation Method 1

by making an internal pressure of a trouble non-occurrence chamber which is a chamber shielding a portion other than a portion where a trouble occurs positive by supply of aseptic air

Methodology Applied

Scientific EffectPositive pressure: Pressure Increase

Data Source

PatentUS11535502B2Trouble recovering method of aseptic filling machine and aseptic filling machine

Publication Date: 2022.12.27 DAI NIPPON PRINTING CO LTD

AI summary

A trouble recovering method of an aseptic filling machine and an aseptic filling machine which can resume operation at an early stage if a trouble occurs in any of portions during an operation of the aseptic filling machine are provided.A door of a chamber in which the trouble occurred is opened while a pressure in the chamber other than the chamber in which the trouble occurred is kept positive, the trouble is removed and then, the door is closed, an inside of the chamber in which the trouble occurred is cleaned as necessary, the inside of the chamber is sterilized and then, the operation of the aseptic filling machine is resumed.