Aseptic Filling Wheel Control for Faster CIP, COP, SOP, and SIP
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Solution Overview
Problem
Conventional aseptic filling apparatuses face prolonged downtime and reduced productivity due to the need to stop wheel rotation during CIP and SIP processes, leading to incomplete cleaning and sterilization of complex filling nozzles and increased downtime.
Innovation Solution
Implement a method where CIP of the content filling station is performed with stopped rotation, followed by COP and SOP while the wheel is rotating, and simultaneous or sequential SOP of other stations is conducted during SIP or CIP/SIP of the content filling station, utilizing clutches or dedicated servo motors to independently control wheel rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wheel rotation is stopped during CIP and SIP processes, then the cleaning and sterilization can be performed, but the decontamination time is prolonged and productivity is reduced
Solution Approach 1:
The system dynamically adjusts wheel rotation state based on process requirements: stopped during CIP/SIP for thorough cleaning, rotating during COP/SOP for continuous operation. This dynamic control resolves the contradiction by making the system adaptable to different operational phases.
Solution Approach 2:
The decontamination process is segmented into distinct phases (CIP, SIP, COP, SOP) with different wheel rotation requirements. By dividing the process and allowing independent control of each phase, the system achieves both thorough cleaning when needed and continuous productivity when possible.
2Reliability
If the wheel rotation is stopped during CIP and SIP processes, then the cleaning and sterilization can be performed, but the cleaning completeness is insufficient for complex filling nozzles
Solution Approach 1:
The wheel rotation is dynamically controlled to be stopped during CIP and SIP for complete cleaning of complex filling nozzles, while allowing rotation during COP and SOP. This dynamic adjustment ensures sterilization completeness without unnecessarily extending total decontamination time.
Solution Approach 2:
The CIP process is performed with stopped rotation as a preliminary thorough cleaning step, followed by SIP for sterilization. This preliminary action with proper wheel control ensures complete cleaning of complex nozzle structures before resuming production.
3Productivity
If the wheel rotation is continuously maintained, then productivity is maintained, but the cleaning and sterilization effectiveness is reduced
Solution Approach 1:
The system dynamically switches between continuous rotation (for productivity) and stopped rotation (for cleaning effectiveness) based on the specific decontamination phase, achieving both goals at different times in the overall process.
Solution Approach 2:
The decontamination process uses periodic action with distinct phases: stopped rotation for CIP/SIP to ensure cleaning quality, then rotating for COP/SOP to maintain productivity. This periodic alternation resolves the contradiction between continuous operation and effective cleaning.
4Reliability
If the wheel rotation is stopped during CIP and SIP, then decontamination can be performed, but the overall production efficiency is reduced
Solution Approach 1:
The wheel rotation control is dynamically optimized: stopped during critical CIP/SIP phases for decontamination quality, rotating during COP/SOP phases to maintain production efficiency. This dynamic control minimizes the impact on overall production efficiency while ensuring decontamination quality.
Solution Approach 2:
The decontamination process is segmented into phases with different productivity impacts. By stopping rotation only during essential CIP/SIP phases and maintaining rotation during COP/SOP phases, the system minimizes total production loss while ensuring decontamination quality.
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
Enhances cleaning and sterilization efficiency, reduces overall decontamination time, and minimizes production downtime, allowing earlier resumption of drink filling operations.
Implementation Method 1
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
Implementation Method 2
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
Implementation Method 3
there is arranged a nozzle that blasts mist of a hydrogen peroxide solution, which is a sterilizer, to the container moving around a wheel
Data Source
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AI summary
The present invention relates to an aseptic filling apparatus, comprising various kinds of stations including a content filling station (6) arranged from an upstream side to a downstream side of a flow of a preform (1) or container fed by rotation of wheels in a wheel train, each of the various kinds of stations being covered by a chamber, wherein the apparatus is characterized by: being configured to perform a Cleaning In Place, CIP, of the content filling station (6) after rotation of only a wheel (9) in the content filling station (6) is stopped, being configured to perform a Cleaning Out of Place, COP, or Sterilizing Out of Place, SOP, of the content filling station (6) while the wheel (9) in the content filling station (6) is rotating immediately after the CIP is completed, being configured to perform a Sterilizing In Place, SIP, of the content filling station (6) with rotation of the wheel (9) in the content filling station (6) being stopped immediately after the COP or SOP is completed, and being configured to perform one or both of the COP and SOP of the other stations in a predetermined order while wheels in the other stations are rotating in a period from the start of the CIP to the end of the SIP.