Aseptic Filling Machine Piping Segmentation for CIP SIP Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Aseptic filling machines face inefficiencies in Cleaning in Place (CIP) and Sterilizing in Place (SIP) processes due to long flow paths in drink supply piping, leading to prolonged times and increased costs, especially with the rise in filling speed and surge tank volume, which reduces machine availability and productivity.
Innovation Solution
The drink supply piping is divided into upstream, aseptic surge tank, and downstream portions, each with dedicated circulation paths for CIP and SIP, allowing for simultaneous or sequential temperature raising of cleaning liquids to sterilization temperatures, and using heated steam for SIP, with backpressure valves to maintain pressure and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drink supply piping is divided into upstream and downstream portions with individual CIP and SIP processes, then the cleaning and sterilization can be performed more effectively, but the time required for CIP and SIP increases due to the long flow path
Solution Approach 1:
The drink supply piping is divided into upstream piping (from drink input tank to filling nozzles) and downstream piping (from aseptic surge tank to filling nozzles), with each portion having its own circulation path for CIP and SIP. This segmentation allows independent processing of each section, improving cleaning effectiveness while enabling parallel execution to reduce total time.
Solution Approach 2:
The circulation paths enable continuous circulation of cleaning liquid and sterilizer through the piping system. By maintaining continuous flow and circulation rather than batch processing, the system achieves thorough cleaning and sterilization while optimizing the use of time and resources.
2Temperature
If cleaning liquid and sterilizer are heated in the upstream portion of the flow path, then the cleaning and sterilization processes can be performed, but the liquid cools down before reaching the filling nozzles due to the long flow path
Solution Approach 1:
The system divides the flow path into upstream and downstream portions, each with dedicated circulation paths. This allows the upstream portion to be heated independently while the downstream portion maintains temperature through its own circulation, preventing cooling over the long distance to filling nozzles.
Solution Approach 2:
The circulation paths act as intermediaries that maintain temperature between the heating location and the filling nozzles. By circulating the cleaning liquid and sterilizer through controlled paths with heat retention capabilities, the system prevents temperature drop over the long flow path.
3Reliability
If a large amount of cleaning liquid and rinse liquid are required to perform CIP and SIP of all filling nozzles simultaneously, then thorough cleaning can be achieved, but the complexity and resource requirements increase
Solution Approach 1:
The filling nozzles are divided into multiple groups, with each group having its own circulation path for CIP and SIP. This segmentation allows simultaneous processing of multiple nozzle groups using separate, manageable circulation systems rather than requiring a single complex system to handle all nozzles at once with large volumes of liquid.
Solution Approach 2:
The circulation paths are designed to be multi-functional, serving both CIP and SIP functions for different nozzle groups. This universality reduces overall system complexity by using standardized circulation path designs that can be replicated and configured for different cleaning and sterilization requirements.
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 significantly reduces the time required for CIP and SIP, enhances cleaning effectiveness, and improves production efficiency by allowing concurrent or sequential processing, thus increasing the availability and productivity of the aseptic filling machine.
Implementation Method 1
heating the cleaning liquid used for CIP to a temperature required for SIP
Implementation Method 2
SIP is performed by passing a heated steam or heated liquid through the drink supply piping cleaned by CIP
Implementation Method 3
backpressure valves to maintain pressure and efficiency
Data Source
AI summary
To efficiently perform CIP and SIP of an aseptic filling machine.An upstream piping portion of a drink supply piping of an aseptic filling machine that extends through a heat sterilization apparatus is provided with an upstream feedback path to form an upstream circulation path, an aseptic surge tank piping portion that includes an aseptic surge tank that stores a drink sterilized by the heat sterilization apparatus is provided with an aseptic surge tank feedback path to form an aseptic surge tank circulation path, a downstream piping portion that extends to a filling nozzle via a filler tank that stores the drink supplied from the aseptic surge tank is provided with a downstream feedback path to form a downstream circulation path, and the upstream piping portion, the aseptic surge tank piping portion and the downstream piping portion are individually subjected to CIP and SIP.