Blow Molding Machine Sterilization via Liquid Diffusion

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Solution Overview

Problem

Aseptic filling machines face challenges in maintaining the aseptic condition of preforms and bottles during the heating and blow molding process, as sterilizers can diffuse inside the heating furnace or not be completely distributed, leading to potential contamination and inefficiencies in sterilization, particularly in the heating unit and molding unit of blow molding machines.

Innovation Solution

A method and apparatus that fill a liquid sterilizer into preforms, which are then heated and used to diffuse and sterilize the heating unit and molding unit components, including spindles, blow nozzles, and conduits, without requiring a large-scale CIP system, ensuring aseptic conditions are maintained during the blow molding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sterilizer is applied to preforms during continuous conveyance and then heated in a heating furnace, then the preforms are sterilized, but the sterilizer may diffuse inside the heating furnace causing contamination or incomplete sterilization

Engineering Contradiction:

Improvesterilization effectivenessVSAvoidsterilizer diffusion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sterilizer is applied to preforms before they enter the heating furnace, and the heating process simultaneously activates and diffuses the sterilizer throughout the heating furnace environment, sterilizing both the preforms and the furnace interior in one integrated process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sterilization of preforms and the sterilization of the heating furnace interior are merged into a single process by utilizing the heating furnace itself as the sterilization chamber, eliminating the need for separate sterilization equipment

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If a CIP system is installed to clean the inside of the blow molding machine after opening, then cleaning is achieved, but additional equipment is required increasing system complexity

Engineering Contradiction:

Improvecleaning capabilityVSAvoidequipment requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The heating furnace serves multiple functions: it heats preforms for blow molding, sterilizes the preforms, and sterilizes the interior of the furnace itself, eliminating the need for separate CIP systems or cleaning equipment

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The blow molding machine sterilizes itself by utilizing the heating furnace to diffuse sterilizer throughout the interior components including the mold, blow nozzle, and extension rod during the normal heating operation

Inventive Principle:

Principle #25Self-service

3Ease of operation

If the blow molding machine is opened for inspection or maintenance, then access is gained, but bacteria or contaminants may enter and adhere to mold or extension rod

Engineering Contradiction:

ImproveaccessibilityVSAvoidcontamination risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The heating furnace continuously sterilizes the interior components including the mold and extension rod by diffusing sterilizer during normal operation, maintaining a sterile state before opening and enabling quick re-sterilization after opening

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sterilization process continues continuously during the heating phase of blow molding, maintaining constant sterilization of the interior components rather than periodic sterilization, ensuring ongoing protection against contamination

Inventive Principle:

Principle #20Continuity of useful action

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

This approach allows for efficient sterilization of critical components in the blow molding machine, maintaining aseptic conditions and preventing contamination, thereby ensuring the production of aseptic bottles without the need for extensive cleaning equipment or prolonged drying processes.

Implementation Method 1

a heating unit that heats the preform to a temperature suitable for molding

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the sterilizer that is applied to the preforms is simultaneously dried and activated by the heating

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

there is also a possibility that the sterilizer will not be completely diffused and some of the sterilizer will remain in the bottle

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS12076906B2Method for sterilizing blow molding machine, and blow molding machine

Publication Date: 2024.09.03 DAI NIPPON PRINTING CO LTD

AI summary

A blow molding machine is subjected to a sterilizing treatment in a simple manner. A liquid sterilizer is filled into preforms of at least the same number as the number of spindles. In a heating unit that heats the preforms to a molding temperature, some of the liquid sterilizer is caused to diffuse, and blow air is blasted into preforms in which the liquid sterilizer remains to cause the liquid sterilizer to diffuse in a molding unit, and molded bottles are discharged.