Blow-Molding Sterilization via UV Radiation on Stretching Rod
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Solution Overview
Problem
Existing methods for sterilizing preforms and blow-molded containers are complex, inefficient, and fail to ensure reliable sterility, particularly in high-output manufacturing environments, with issues such as uncontrolled leakage of sterilization means and difficulty in maintaining sterility of the stretching rod and blowing nozzle.
Innovation Solution
Incorporating a sterilization installation with a radiation source, such as UV emitters, in the blowing station to emit sterilizing radiation onto the stretching rod and/or blowing nozzle, allowing for non-contact sterilization that is independent of the blowing process and can operate continuously, including during interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sterilization means are applied to preforms using separate treatment stations, then sterilization is achieved, but the process becomes complex and unreliable with uncontrolled leakage
Solution Approach 1:
The sterilization installation is merged with the blowing station, combining two previously separate functions (sterilization and blow-molding) into a single integrated system. This eliminates the need for separate treatment stations and reduces process complexity while maintaining sterilization effectiveness.
Solution Approach 2:
The blowing station is given multi-functionality by incorporating sterilization capabilities. The same station that performs blow-molding now also performs sterilization of preforms, stretching rods, and blowing nozzles, reducing the number of dedicated sterilization stations needed.
2Reliability
If external sterilization procedures are used for stretching rod and blowing nozzle, then sterility is maintained, but labor-intensive procedures are required
Solution Approach 1:
The stretching rod and blowing nozzle perform self-sterilization by being irradiated by UV radiation sources during their operation in the blowing station. This eliminates the need for external sterilization procedures and manual intervention, making the process automated and simpler to operate.
Solution Approach 2:
The sterilization of stretching rod and blowing nozzle occurs continuously during the blow-molding operation rather than requiring separate sterilization cycles. The UV radiation sources operate concurrently with the blowing process, maintaining sterility without interrupting production.
3Device complexity
If sterilization installation is integrated in blowing station, then process is simplified and sterility is ensured, but radiation sources must be positioned precisely
Solution Approach 1:
UV radiation sources are positioned at specific locations within the blowing station where they can directly irradiate the stretching rod and blowing nozzle. The radiation sources are placed in strategic positions (e.g., above the blowing station, around the stretching rod path) to ensure targeted sterilization of critical 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
This approach simplifies the sterilization process, ensures effective sterility of the stretching rod, blowing nozzle, and preforms without labor-intensive external sterilization procedures, maintaining sterility during operation and preventing germ re-infestation.
Implementation Method 1
a sterilization installation which has at least one radiation source and which emits a sterilizing radiation onto the stretching rod and/or onto the blowing nozzle is disposed in the blowing station
Data Source
AI summary
A method and a device for producing blow-molded containers, which are sterile at least in some areas, in a blow-molding machine. A preform made of a thermoplastic material is first heated, then stretched by a stretching rod in a blowing station, and then supplied with a pressurized fluid via a blow nozzle, wherein a sterilization device is arranged in the blowing station. The sterilization device has at least one radiation source which emits a sterilizing radiation onto the stretching rod and/or onto the blow nozzle.