Aseptic Forming Station Sterile Filter Placement

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Aseptic forming stations for sensitive food products face challenges in minimizing microbiological contamination and oxidation risks due to complex and costly sterilization processes, particularly with the placement of sterile filters that increase recontamination risks and require extensive sterilization of air pressure lines.

Innovation Solution

An aseptic forming station with a sterile filter positioned downstream of the valve means and integrated into the blowing nozzle or conduit, reducing the sterile air path and eliminating the need for sterile blowing valves, while maintaining sterility through a contamination-controlled environment and separate compressed air supply lines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sterile filters are arranged upstream of the blowing valve (in the dirty environment), then the isolation device can contain the filters, but the path between filter and mould becomes long increasing recontamination risks

Engineering Contradiction:

Improvesterility of air pathVSAvoidcomplexity of sterilization circuit

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent inverts the conventional arrangement by placing the sterile filter downstream of the blowing valve rather than upstream. This reversal positions the filter in the sterile environment within the isolation device, eliminating the need to sterilize the long air path between the filter and mould while maintaining sterility at the critical point where air contacts the preform.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts the sterile filter from the dirty environment and places it within the sterile environment of the isolation device. This extraction eliminates the need to maintain sterility of the external air supply circuit and its associated valves, reducing the complexity of the sterilization system while improving reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If sterile filters are arranged on the rotating part of the machine, then the area to be kept sterile is reduced, but mounting difficulties and significant overall dimensions occur

Engineering Contradiction:

Improvesterility maintenance areaVSAvoidmounting ease and compactness

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent segments the air supply system into separate sterile and non-sterile circuits. The sterile filter is positioned in the sterile circuit downstream of the valve, allowing the rotating manifold to remain outside the isolation device or be simplified, while the sterile air is delivered through dedicated lines to each mould station.

Inventive Principle:

Principle #1Segmentation

3Reliability

If blowing valves are made sterile to prevent recontamination, then sterility is maintained, but the design becomes more complex and costly

Engineering Contradiction:

Improvesterility of blowing airVSAvoiddesign complexity of blowing valves

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the blowing valve from the sterile environment and places it in the non-sterile external environment. The sterile filter is positioned downstream within the isolation device, so the valve itself does not need to be sterile or complex. Only the air downstream of the filter needs to remain sterile, which is achieved through the filter placement rather than valve design.

Inventive Principle:

Principle #2Taking out (Extraction)

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 configuration significantly reduces recontamination risks, simplifies the design, and reduces the complexity and cost of maintaining sterility, allowing for efficient production of aseptically formed containers with reduced sterile air circuit lengths.

Implementation Method 1

at least one sterile filter arranged downstream of the valve means

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

compressed air coming from a first compressed air supply line or from a second compressed air supply line is injected into the preform

Methodology Applied

Scientific EffectCompressed air injection: Pressure Gradient

Data Source

PatentEP3904046B1An aseptic forming station for forming a container starting from a preform made of thermoplastic material, an aseptic forming apparatus and process

Publication Date: 2022.06.29 GEA PROCOMAC

Figure 1a~1b
Figure 2~3
Figure 4~5

AI summary

An aseptic forming station (1) for forming a container (100) starting from a preform made of thermoplastic material, comprising: - a blowing nozzle applicable to a mouth (100a) of the preform through which compressed air coming from a first compressed air supply line (4) or from a second compressed air supply line (5) is injected into the preform; - valve means (P1, P2) configured to establish a selective communication between the compressed air supply lines (4, 5) and the blowing nozzle; - at least one sterile filter (SF) arranged downstream of the valve means (P1, P2).