Aseptic Packaging System Fitment Drying and Sterilization
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Solution Overview
Problem
Current aseptic packaging systems face challenges in ensuring the sterility and efficient drying of external fitments attached to packaging films, which can lead to residual hydrogen peroxide contamination and compromise the aseptic integrity of the packaged products.
Innovation Solution
An automated vertical form/fill/seal system that incorporates a fitment feed device, sterilizing, and drying assemblies to attach and dry external fitments on the film surface, utilizing hydrogen peroxide sterilization and sterile air drying to ensure the aseptic integrity of the packaging process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If external fitments are attached to the packaging film in the aseptic packaging system, then the functionality of the package is improved, but the risk of residual hydrogen peroxide contamination increases
Solution Approach 1:
The fitment is attached to the packaging film before the sterilization process. This preliminary attachment allows the fitment to be sterilized together with the film, ensuring that any residual hydrogen peroxide is minimized before the fitment comes into contact with the product compartment.
Solution Approach 2:
The packaging film serves as an intermediary barrier between the sterilization environment and the product compartment. The film is designed to be impermeable to hydrogen peroxide vapor, preventing contamination of the product while allowing the fitment attached to its outer surface to be sterilized.
2Reliability
If the sterilization process is extended to ensure complete drying of external fitments, then the aseptic integrity is improved, but the processing time increases
Solution Approach 1:
The drying function is extracted from the sterilization chamber and performed separately in an air knife section. This allows the sterilization process to be completed independently, and the drying to occur in a dedicated zone using high-velocity sterile air, thereby reducing the overall processing time while maintaining aseptic integrity.
Solution Approach 2:
A high-velocity sterile air stream (air knife) is used to rapidly dry the outer surface of the fitment. The pneumatic force of the air stream efficiently removes moisture without requiring extended thermal drying time, thus maintaining reliability while reducing processing time.
3Productivity
If the air knife section is positioned to dry the outer surface of the fitment, then the drying efficiency is improved, but the positioning precision requirement increases
Solution Approach 1:
The air knife section is designed to dry both the packaging film and the attached fitment simultaneously in a single pass. This multi-functional approach increases drying efficiency without requiring separate positioning adjustments, as the air stream covers the entire width of the film and any fitments attached thereto.
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
The system effectively secures and dries external fitments on the packaging film, ensuring compliance with regulatory standards for residual hydrogen peroxide levels and maintaining the aseptic condition of the packaged products, enhancing the reliability and safety of the packaging process.
Implementation Method 1
Hydrogen peroxide is a common medium for sterilization of the packaging material
Implementation Method 2
drying assemblies to attach and dry external fitments on the film surface, utilizing hydrogen peroxide sterilization and sterile air drying
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
An aseptic packaging system (10) includes a film unwind device (12) a fitment feed device (14) for feeding a plurality of fitments (302) an apparatus (50) for attaching each of the fitments to a second surface of the film (17) an assembly for sterilizing the film and optionally each of the fitments (302) an assembly (18) for drying the film and optionally each of the fitments; and a vertical form/fill seal apparatus (22) for making packages from the sterilized film (141) and each of the fitments, each package (100) comprising a pouch comprising a first (176) and second (178) transverse seal, a first and second fold, an interior and exterior surface, and a longitudinal seal (154) and an external fitment (302) sealed to the exterior surface of the pouch; and a sterilized product disposed in the pouch. An aseptic process and package are also disclosed.