Beverage Packaging Apparatus with Integrated Refrigeration
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Solution Overview
Problem
Small beverage manufacturers face challenges in packaging carbonated beverages due to the lack of affordable, fully automated fill and seal apparatus with integrated refrigeration, leading to issues with CO2 suspension, volume control, and high costs of available solutions.
Innovation Solution
A beverage manufacturing apparatus with integrated refrigeration, UV-C sanitizing, and automated fill and sealing capabilities, including a refrigeration unit, container delivery chute, fill heads with flow meters, and pneumatic actuation for precise control and efficient operation, providing direct inline volume control and cost-effective packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external refrigeration systems are used to keep carbonated beverages cold, then CO2 suspension is maintained, but device complexity and cost increase
Solution Approach 1:
The patent combines the refrigeration system, filling apparatus, and sealing mechanism into a single integrated unit. The refrigeration unit is built into the fill and seal apparatus, eliminating the need for separate external refrigeration systems and reducing overall device complexity while maintaining beverage temperature for CO2 suspension.
Solution Approach 2:
The integrated apparatus performs multiple functions: refrigeration, filling, sealing, and volume verification. The refrigeration unit serves the dual purpose of maintaining beverage temperature during storage and during the filling process, while the flow meter provides both filling control and volume verification functions.
2Productivity
If fully automated fill and seal apparatus are used, then productivity increases, but cost increases making it unaffordable for small manufacturers
Solution Approach 1:
The patent designs a modular automated apparatus where components like the refrigeration unit, fill heads with flow meters, and sealing mechanism can be independently manufactured and assembled. This segmentation allows small manufacturers to build or acquire only the automation level they need, reducing overall cost while maintaining productivity benefits.
3Measurement precision
If external post-packaging weighing is used to verify beverage volume, then measurement accuracy is achieved, but loss of time and reduced productivity occur
Solution Approach 1:
The patent incorporates flow meters in the filling process that measure and verify beverage volume in real-time during filling. This preliminary measurement eliminates the need for post-packaging weighing, as the volume is already verified before the container leaves the filling station, saving time and maintaining productivity.
4Stability of the object's composition
If integrated refrigeration is built into the fill head, then CO2 suspension is maintained during filling, but device complexity increases
Solution Approach 1:
The refrigeration system is merged with the fill head assembly, allowing cold beverage to be delivered directly to the filling point without transferring through warm external hoses. This integration maintains CO2 suspension stability while the modular design keeps the added complexity manageable through standardized components.
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 effectively maintains CO2 suspension in carbonated beverages, ensures precise filling and sealing, and reduces operational costs by integrating refrigeration and automation, making it suitable for small-scale manufacturers while providing direct volume control and reducing waste.
Implementation Method 1
an integrated refrigeration Assembly that holds bulk beverage containers and includes an attachment to an external beverage storage tank
Implementation Method 2
an integrated Sanitization Station that uses UV-C light to sanitize the container prior to fill
Implementation Method 3
Each fill head may have an integrated flow meter to provide precise fluid control
Data Source
AI summary
A beverage packaging apparatus comprises a Refrigeration Assembly that keeps the beverage cold all the way to the fill head. The Refrigeration Assembly also allows manufacturers to fill off smaller beverage containers like kegs or larger storage tanks. The apparatus includes an integrated Container Loading Chute, and a Container Depalletizer having a scoop to depalletize containers. The Container Depalletizer integrates with the Container Loading Chute to provide for seamless flow for the Fill Head Assemblies and Seaming Assembly. The apparatus includes a unique integrated UV-C Sanitizing Station. The apparatus includes a conveyor with three fill head assemblies automated by smooth pneumatic actuation. Each fill head assembly has an integrated flow meter to provide precise fluid control. The apparatus includes a single pneumatic, rotary rack and pinion actuation that provides highly repeatable sealing of the container in a very small footprint without requiring sophisticated software to control the seaming operation. Finally, the apparatus includes rinse and dry assembly for the container and an innovative, integrated Accumulation Assembly to hold the completed beverage containers or packages.