Beverage Injection Device for Sterile PET Bottle Production
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Solution Overview
Problem
Current manufacturing processes for PET bottles struggle to achieve high-volume, cost-effective sterilization of containers, which is crucial for maintaining hygiene standards and extending the shelf life of food products.
Innovation Solution
A method and device that expose preforms to sterilizing fluids, such as steam or hydrogen peroxide, and irradiation, followed by aseptic filling, to reduce microbiological contamination and promote expansion within a mould, ensuring efficient production of sterile beverage bottles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional blow moulding with compressed air is used, then production speed is high, but sterilization effectiveness is insufficient
Solution Approach 1:
The patent combines the sterilization function and filling function into a single integrated device. The sterilization circuit delivers sterilizing fluid to the preform, while the filling circuit delivers beverage to the same preform within the mould cavity, eliminating the need for separate sterilization and filling operations and maintaining high production speed while achieving effective sterilization.
Solution Approach 2:
The sterilization of the preform is performed before the filling operation within the same mould cavity. The sterilizing fluid is delivered to the preform first, followed by the beverage filling, ensuring that sterilization is completed prior to product introduction while maintaining continuous production flow.
2Reliability
If separate sterilization and filling processes are used, then sterilization can be thorough, but production cost increases and productivity decreases
Solution Approach 1:
The patent merges the sterilization circuit and filling circuit into a single integrated device with common components such as the mould cavity and control systems. This integration reduces device complexity while maintaining thorough sterilization effectiveness, as both functions operate within the same controlled environment.
Solution Approach 2:
The mould cavity serves multiple functions: it acts as the sterilization chamber for delivering sterilizing fluid to the preform, and simultaneously serves as the filling chamber for introducing the beverage. This multi-functionality eliminates the need for separate dedicated chambers, reducing overall system complexity.
3Reliability
If multiple separate circuits for sterilization and filling are used, then each function can be optimized, but the aseptic zone size increases and production efficiency decreases
Solution Approach 1:
The patent combines the sterilization circuit and filling circuit into a single integrated system where both functions operate within the same confined aseptic zone (the mould cavity). This integration maintains a small aseptic zone size while achieving both sterilization and filling objectives, thereby preserving high production rates.
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
Enables the production of high-sterility beverage bottles in large quantities at a low cost, with significant microbiological reduction and improved hygiene, ensuring longer product life and compliance with sanitary standards.
Implementation Method 1
a prior step of exposing the preform to a sterilizing fluid supplied by a first circuit connected to the injection head
Implementation Method 2
injecting, into a recess of the preform, at least some of the beverage supplied by a second circuit connected to the injection head so as to promote expansion of the preform inside the mould
Implementation Method 3
the method further includes a step of irradiating the preform with sterilizing radiation. This irradiating step may comprise irradiation of the preform with X-rays. Alternatively, or optionally in combination, the irradiating step comprises irradiation of the preform with microwaves.
Data Source
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AI summary
The invention relates to a device for delivering a predetermined volume of beverage into a thermoplastic container formed from a preform, comprising: - an injection head (18) - an actuator (15) to connect the injection head to the neck of the preform, and - means for injecting, into a recess of the preform, at least some of the beverage supplied by a circuit connected to the injection head so as to promote expansion of the preform inside a mould. The actuator comprises a chamber (15c) connected to a line (32) via which the beverage is fed in, the actuator comprising a control cylinder for controlling the injection head (18), the control cylinder having a lateral opening allowing the beverage to circulate between the chamber (15c) and the inside of the control cylinder.