Aseptic ROPP Cap Sterilization for Aluminium and Glass Filling

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Solution Overview

Problem

Existing ROPP capping machines for Aluminium and glass receptacles are complex, require lengthy cleaning and sterilizing steps, consume high energy, and are difficult to maintain, posing challenges in aseptic applications where microbiological contamination must be controlled.

Innovation Solution

An aseptic apparatus and process that includes a filling unit, a ROPP capping unit within an isolator, a transfer star-wheel, and a treating device to sterilize ROPP screw caps using a sterilizing substance or radiation, ensuring sterility and reducing complexity and energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a ROPP capping machine is used to close Aluminium or glass receptacles, then the receptacles can be properly sealed with threaded closures, but the machine complexity and number of components increase significantly

Engineering Contradiction:

Improvesealing reliabilityVSAvoidcapping machine complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the thread-forming function from a complex ROPP capping machine and implements it using a simple external threading tool that applies threads to the receptacle neck externally, eliminating the need for complex internal thread-cutting mechanisms and high-precision ROPP capping heads

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of creating internal threads in the closure cap as in traditional ROPP capping, the invention inverts the approach by creating external threads on the receptacle neck, allowing the closure to screw onto the receptacle in reverse orientation, thereby simplifying the capping mechanism

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If a ROPP capping machine is used to close Aluminium or glass receptacles, then proper sealing is achieved, but cleaning and sterilizing steps become longer and more complicated

Engineering Contradiction:

Improvesealing reliabilityVSAvoidcleaning and sterilizing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent segments the capping function into separate, easily cleanable components: a simple external threading tool, a basic capping head, and a transfer mechanism. Each component has smooth surfaces without complex internal geometries, allowing rapid cleaning and sterilization cycles

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses simple, easily replaceable capping components with smooth, non-porous surfaces that can be quickly sanitized or replaced between batches, eliminating the need for lengthy sterilization procedures required by complex ROPP machines

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If a ROPP capping machine is used to close Aluminium or glass receptacles, then sealing is achieved, but energy consumption increases

Engineering Contradiction:

Improvesealing reliabilityVSAvoidcapping machine energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the high-energy ROPP capping mechanism with a low-energy external threading system that uses simple rotational motion and basic pressing forces, eliminating the need for high-power motors and complex mechanical systems required by traditional ROPP capping machines

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If a ROPP capping machine is used to close Aluminium or glass receptacles, then sealing is achieved, but maintenance operations become more complex and time-consuming

Engineering Contradiction:

Improvesealing reliabilityVSAvoidcapping machine maintenance

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The capping system is divided into modular, easily accessible components including the external threading tool, capping head, and transfer mechanism. Each module can be independently maintained, adjusted, or replaced without disassembling complex mechanical systems, greatly simplifying maintenance operations

Inventive Principle:

Principle #1Segmentation

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 apparatus and process ensure sterility, reduce complexity and energy consumption, and facilitate easier maintenance while preserving the organoleptic properties of sensitive food products.

Implementation Method 1

a treating device configured to sterilize the ROPP screw caps while they linearly advance along a conveying path inside the treating device

Methodology Applied

Scientific EffectRadiation: Radiation

Implementation Method 2

a dispensing pipe configured to dispense a sterilizing substance inside the treating chamber

Methodology Applied

Scientific EffectSterilization by sterilizing substance: Hydrogen Peroxide

Data Source

PatentEP4647392A1An aseptic apparatus and process for filling and closing aluminium or glass receptacles

Publication Date: 2025.11.12 GEA PROCOMAC

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AI summary

An aseptic apparatus (1) for filling and closing Aluminium or glass receptacles (100) with ROPP screw caps (101), the aseptic apparatus (1) comprising: - a filling unit (13) configured to inject a product within the receptacles (100); - a ROPP capping unit (10) arranged downstream the filling unit (13) and being configured to apply on the receptacles (100) the ROPP screw caps (101) already sterilized; - an isolator (11) delimiting a controlled-contamination environment (12), the filling unit (13) and the ROPP capping unit (10) being arranged inside the isolator (11).