Aseptic Filling Decontamination via Parallel CIP SIP SOP
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Solution Overview
Problem
The existing aseptic filling apparatus experiences prolonged downtime and reduced productivity due to the sequential performance of CIP, SIP, COP, and SOP processes, which leads to incomplete sterilization of stations and potential contamination, especially with complex-shaped filling nozzles.
Innovation Solution
The method involves performing CIP and SIP concurrently on the content filling station, followed by stepwise execution of first and second SOPs using different sterilizers while the CIP and SIP are ongoing, allowing for simultaneous decontamination of all stations, including the content filling, container sterilizing, and container sealing stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If CIP, SIP, COP, and SOP are performed sequentially on the aseptic filling apparatus, then each process can be completed thoroughly, but the total decontamination time increases significantly, reducing productivity
Solution Approach 1:
The patent combines CIP and SIP processes to occur simultaneously in the content filling station, and overlays SOP processes on other stations during these operations. This merging of previously sequential processes into parallel operations reduces total decontamination time while maintaining sterilization effectiveness through coordinated multi-station treatment.
Solution Approach 2:
The patent implements continuous decontamination by performing CIP, SIP, and SOP processes in an overlapping manner across different stations rather than stopping production for complete sequential treatment. The useful action of sterilization continues across multiple stations simultaneously, minimizing idle time and maintaining production flow.
2Manufacturing precision
If the filling nozzles have complex shapes to achieve precise filling, then filling precision is improved, but the sterilization effectiveness deteriorates due to difficult-to-reach areas
Solution Approach 1:
The patent combines CIP (chemical cleaning) and SIP (steam sterilization) processes to occur simultaneously on the filling nozzles. The CIP phase addresses complex geometry cleaning with chemical agents, while the SIP phase provides comprehensive thermal sterilization that penetrates difficult-to-reach areas, together achieving both precise cleaning and reliable sterilization of complex-shaped components.
Solution Approach 2:
The patent employs parameter changes by using different physical and chemical states - chemical agents during CIP for penetrating complex geometries, followed by thermal parameters during SIP with steam and heat to ensure complete sterilization. This multi-parameter approach overcomes the sterilization challenges of complex nozzle shapes.
3Reliability
If multiple sterilization processes are performed in sequence to ensure complete sterilization, then sterilization reliability is improved, but the downtime increases and production efficiency decreases
Solution Approach 1:
The patent merges multiple sterilization processes by performing CIP and SIP simultaneously on the content filling station while conducting SOP on other stations. This parallel execution of previously sequential sterilization processes maintains sterilization reliability through comprehensive multi-stage treatment while dramatically reducing total downtime by eliminating idle waiting periods between processes.
Solution Approach 2:
The patent applies preliminary action by performing CIP (chemical pre-treatment) simultaneously with SOP on other stations before the final SIP sterilization. This preliminary chemical cleaning and concurrent sterilization of other components prepares the system for final sterilization while minimizing overall downtime through coordinated preliminary actions across multiple stations.
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 the overall decontamination time, enhances the cleaning and sterilization effectiveness of all stations, and minimizes downtime, enabling earlier resumption of drink filling operations and improving production efficiency.
Implementation Method 1
there is arranged a nozzle that blasts mist of a hydrogen peroxide solution, which is a sterilizer, to the container moving around a wheel
Implementation Method 2
The CIP is performed by flowing a cleaning liquid through a flow path from the interior of the drink supply piping to the filling nozzles in the filler, the cleaning liquid containing water and an alkali agent such as sodium hydroxide or potassium hydroxide or an acidic agent such as nitric acid as an additive
Implementation Method 3
The SIP is performed by flowing a vapor, hot water or the like through the piping cleaned by the CIP, and the interior of the drink supply piping is sterilized by being heated by the vapor, hot water or the like
Data Source
AI summary
A method of decontaminating an aseptic filling apparatus that includes stations including a content filling station arranged from an upstream side to a downstream side of a flow of a preform or container, and each of the stations is covered by a chamber. The method includes sterilizing the content filling station by performing a CIP and then an SIP or performing an SIP serving also as a CIP of the content filling station, removing a cleaning liquid used in the CIP or SIP, and performing a COP and/or an SOP of the various kinds of stations in a predetermined order. A first SOP using a first sterilizer and a second SOP using a second sterilizer are performed stepwise on the various kinds of stations while the CIP and the SIP or the SIP serving also as the CIP are being performed on the content filling station.