Aseptic Dispensing System Using Microwave Heating and Sterile Air

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Solution Overview

Problem

Current aseptic dispensing systems for non-acidic food products like milk face contamination risks due to the attachment of dispensing devices, which compromises the sterility and shelf life of the product, especially when not maintained under refrigeration.

Innovation Solution

A system that aseptically dispenses commercially sterile foods from an aseptic bag by heating the product to near boiling using a presterilized hose and peristaltic pump, then transferring it to a consumer container while maintaining asepticity, using a microwave for heating and over-pressurizing with sterile air to prevent contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a dispensing device is attached to the pouch at the point of use, then convenient dispensing of the product is achieved, but the integrity of the pouch is violated and there is a risk that bacteria on the dispensing device may contaminate the content of the pouch

Engineering Contradiction:

Improveconvenient dispensingVSAvoidsterility maintenance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The pouch and dispensing device are sterilized before use. The pouch is sterilized during manufacturing and sealed, while the dispensing device is sterilized by autoclaving or other appropriate methods before attachment to the pouch at the point of use.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A sterile barrier or interface mechanism is introduced between the pouch and dispensing device to maintain sterility. This may include sterile adapters, sealing mechanisms, or barrier films that allow connection while preventing bacterial transfer.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the pouch is opened and the product is dispensed, then the product can be used, but the shelf life of the product is considerably lowered due to contamination by connecting a foreign member to the pouch

Engineering Contradiction:

Improveproduct dispensingVSAvoidshelf life

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The pouch is sterilized during manufacturing and sealed in a sterile environment. The dispensing device is pre-sterilized before attachment, ensuring both components are free from contamination before the product is dispensed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pouch and/or dispensing device may be designed as single-use disposable items that are discarded after one use, eliminating the risk of repeated contamination from re-attachment and ensuring the product maintains its shelf life characteristics.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If the product is heated to excessive temperatures, then the product can be pasteurized or sterilized, but the desired taste is adversely affected

Engineering Contradiction:

ImprovesterilizationVSAvoidtaste degradation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The heating parameters (temperature, time, pressure) are precisely controlled and optimized to achieve sterilization at the lowest effective temperature. This may involve using high pressure to lower the boiling point, or using pulsed heating cycles to achieve sterilization without excessive thermal exposure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Traditional thermal sterilization is replaced or supplemented with alternative sterilization methods such as high pressure processing (HPP), ultrasonic treatment, or irradiation, which can achieve sterilization without exposing the product to excessive temperatures that would degrade taste.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 maintains the sterility of the product during dispensing, preventing microbiological growth and airborne contamination, ensuring the product's quality and extending its shelf life.

Implementation Method 1

The tubing is preferably fed through a peristaltic pump and then introduced into a microwave cavity. The product is heated from ambient to the desired temperature using conventional microwave absorption heating

Methodology Applied

Scientific EffectMicrowave heating: Dielectric Heating

Implementation Method 2

The tubing is preferably fed through a peristaltic pump

Methodology Applied

Scientific EffectPeristalsis: Peristalsis

Implementation Method 3

The dispensing port is preferably over-pressured with sterile air to prevent airborne contamination of the dispensing port and aseptic tubing

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS7595470B1Method and apparatus for heating and aseptic dispensing of sterile product

Publication Date: 2009.09.29 DAIRYVATIVE TECHNOLOGIES LLC

AI summary

A method and apparatus (20) for heating and dispensing a sterile product is disclosed herein. The apparatus (20) preferably includes a source of the sterile product (25), a flow containment means (30), a pumping means (35), a heating means (40) and a dispenser (45). Preferably, the sterile product is sterile milk which is pumped from an aseptic bag (25) through tubing (30) using a peristaltic pump (35). Then, the sterile milk is heated within tubing positioned within a microwave oven (40), and then flowed to a dispenser (45).