Aseptic Container Forming Through Sterilizing Liquid Expansion
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Solution Overview
Problem
Existing blow molding processes for plastic containers face challenges in achieving aseptic conditions without exposing end products to high temperatures, which can affect product properties and require complex container configurations to manage pressure differentials.
Innovation Solution
A method and system using a sterilizing liquid to expand and form a container within a mold cavity, followed by draining and rinsing to achieve aseptic conditions, allowing for the introduction of end products at ambient temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hot filling process is used to sterilize the container and product, then sterilization is achieved, but the end product is adversely affected by high temperature exposure
Solution Approach 1:
The container is sterilized in advance during the blow molding process using steam or chemical sterilization of the mold cavity, before the end product is introduced. This eliminates the need for hot filling, as the container is already sterile when the product is added at ambient temperature.
Solution Approach 2:
The sterilization process is separated from the filling process. Sterilization is performed on the empty container during molding, while filling occurs separately at ambient temperature, avoiding simultaneous exposure of the product to high temperatures.
2Reliability
If hot filling is used to sterilize the container, then sterilization is achieved, but complex container configurations are required to manage pressure differentials during cooling
Solution Approach 1:
The container is sterilized in advance during the blow molding process using steam or chemical sterilization of the mold cavity, before the end product is introduced. This eliminates the need for hot filling, as the container is already sterile when the product is added at ambient temperature.
3Productivity
If conventional blow molding with gas is used, then container formation is achieved, but energy efficiency is reduced compared to liquid expansion
Solution Approach 1:
The invention uses liquid (hydraulic) pressure instead of gas (pneumatic) to expand the preform. Liquid is incompressible and transfers pressure more efficiently, reducing energy loss and improving the efficiency of container formation.
4Productivity
If the end product is used as the liquid expansion means, then transportation and intermediate handling steps are eliminated, but the product is exposed to high temperatures during sterilization
Solution Approach 1:
The container is sterilized in advance during the blow molding process using steam or chemical sterilization of the mold cavity, before the end product is introduced. This eliminates the need for hot filling, as the container is already sterile when the product is added at ambient temperature.
Solution Approach 2:
The sterilization process is separated from the filling process. Sterilization is performed on the empty container during molding, while filling occurs separately at ambient temperature, avoiding simultaneous exposure of the product to high temperatures.
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 method ensures aseptic formation and filling of containers without high-temperature exposure, reducing complexity and maintaining product integrity while minimizing infrastructure and labor costs.
Implementation Method 1
dispensing a sterilizing liquid into the container precursor to expand the container precursor against the internal surface of the mold cavity
Implementation Method 2
the sterilizing liquid sterilizing the interior surface of the resultant container during the dispensing of the sterilizing liquid
Data Source
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Figure 6
AI summary
A method of forming and sterilizing a container includes steps of locating a container precursor within a mold cavity having an internal surface, dispensing a sterilizing liquid into the container precursor to expand the container precursor toward the internal surface of the mold cavity to form a resultant container having an interior defined by an interior surface of the resultant container with the sterilizing liquid sterilizing the interior surface of the resultant container during the dispensing of the sterilizing liquid, draining the sterilizing liquid from the interior of the resultant container, rinsing the interior of the resultant container with a rinsing liquid following the draining of the sterilizing liquid, dispensing an end product into the interior of the resultant container following the rinsing of the interior of the resultant container, and sealing the interior of the resultant container following the dispensing of the end product therein.