Automated Bulk Ingredient Batching for High-Speed Bottling
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Solution Overview
Problem
The manual batching process for liquid product ingredients is prone to operator error and inefficient, leading to bottling line pauses due to the inability to maintain pace with high-speed production.
Innovation Solution
An automated ingredient preparation and batching system with pre-mix stations and holding tanks for major ingredients, coupled to a batch tank, which uses flow meters and pumps to accurately and quickly combine ingredients based on recipes, decoupling major and minor ingredient preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual batching process is used, then quality tracking and operator control are maintained, but production efficiency decreases and operator error increases
Solution Approach 1:
The system uses automated flow meters and pumps to self-regulate ingredient dispensing based on recipe requirements, eliminating the need for manual measurement and reducing operator error while maintaining quality tracking through automated recording of batch compositions
Solution Approach 2:
The patent replaces manual mechanical batching operations with an automated control system that uses electronic flow meters and programmable logic to precisely control ingredient dispensing, thereby increasing speed while maintaining or improving quality consistency
2Adaptability or versatility
If manual batching is used, then flexibility in batch composition is maintained, but production pace cannot keep up with high-speed bottling lines
Solution Approach 1:
The system employs dynamically adjustable flow meters and pumps that can be programmatically controlled to dispense varying quantities of ingredients at different rates, allowing flexible batch compositions to be rapidly prepared to match bottling line speed requirements
Solution Approach 2:
The automated system can quickly change dispensing parameters (flow rates, volumes, timing) through programmable control, enabling rapid adaptation to different batch compositions and speeds without the delays inherent in manual adjustment
3Productivity
If automated batching is implemented, then batching speed increases, but system complexity increases
Solution Approach 1:
The automated batching system uses multi-functional components such as flow meters and pumps that can handle multiple ingredients and operate in various modes, reducing the overall number of specialized components needed while maintaining high batching speed and flexibility
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 efficiently creates new batches in 30-40% less time than manual methods, ensuring quality and safety, and maintains production line speed by preparing ingredients in bulk, reducing operator intervention.
Implementation Method 1
The batch tank is configured to receive a predetermined quantity of the hydrated ingredient from the holding tank
Data Source
AI summary
A production line for bottling a liquid product includes an ingredient preparation and batching system. The ingredient preparation and batching system includes a pre-mix station including a holding tank configured to store a hydrated ingredient. The ingredient preparation and batching system also includes a batch tank fluidly coupled to the pre-mix station and configured to receive a predetermined quantity of the hydrated ingredient from the holding tank. The production line also includes a bottling line fluidly coupled to the batch tank and configured to receive a batch of the liquid product from the batch tank and dispense the batch of the liquid product into a plurality of containers.