Buffer-Free Pasteurization and Filling System
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Solution Overview
Problem
Conventional pasteurization and filling systems require significant space and intermediate storage volume, leading to inefficiencies and potential thermal overload due to double pasteurization of excess beverages, which can result in product impairment.
Innovation Solution
A buffer-free pasteurization and filling device with a single buffer container and a rotary filling system, where the filling device is directly connected to the buffer container, reducing storage needs and eliminating the risk of double pasteurization through a proportional valve and control device that adjusts filling flow and temperature to maintain optimal pasteurization levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a buffer tank and filler vessel are used in the pasteurization and filling system, then the system can maintain consistent beverage flow and handle disturbances in the filling process, but the device requires significant space and stores substantial amounts of medium intermediately
Solution Approach 1:
The patent removes the filler vessel from the system, extracting the component that causes excessive storage space requirements. The beverage flows directly from the pasteurizer to the filler without intermediate storage, eliminating the need for large-volume stationary containers while maintaining flow consistency through direct pneumatic transfer.
Solution Approach 2:
The patent introduces a pneumatic transfer system as an intermediary mechanism between the pasteurizer and filler. This pneumatic system acts as a mediator that maintains consistent beverage flow and handles disturbances without requiring intermediate storage tanks, using gas pressure control instead of volumetric storage.
2Reliability
If beverage is returned through a bypass line bypassing the pasteurizer when flow exceeds filling capacity, then the filling machine can be protected from overload, but thermal overload due to partial double pasteurization occurs which can impair the product
Solution Approach 1:
The patent removes the bypass line from the system, extracting the component that causes thermal overload. By eliminating the bypass, all beverage must pass through the pasteurizer, preventing double pasteurization and thermal overload while still protecting the filling machine through direct pneumatic control of flow rate.
Solution Approach 2:
The patent changes the control parameter from flow rate regulation (which causes bypassing) to pneumatic pressure control. By regulating the pneumatic pressure in the transfer line, the system maintains optimal flow to the filler without exceeding capacity, eliminating the need for bypassing and subsequent thermal overload.
3Loss of substance
If a buffer-free connection is used between the buffer container and filling device, then storage requirements are minimized and waste is reduced, but the system requires precise control to maintain optimal pasteurization levels
Solution Approach 1:
The patent implements a feedback control system that monitors beverage flow and pneumatic pressure in real-time. This feedback mechanism allows the system to maintain optimal pasteurization levels and flow rates without requiring large buffer volumes, automatically adjusting parameters to prevent waste while ensuring consistent processing conditions.
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 configuration minimizes storage requirements, reduces waste, and prevents thermal overload, ensuring efficient and consistent pasteurization while maintaining product quality by eliminating the need for a secondary buffer tank and optimizing the filling process.
Implementation Method 1
a short time heating system for pasteurizing the medium
Implementation Method 2
a proportional valve and a control device for adjusting the filling flow and the temperature
Implementation Method 3
a single buffer container downstream of the short time heating system for receiving the medium
Data Source
AI summary
A device for pasteurizing and filling medium into containers includes a short time heating system for pasteurizing the medium, a single buffer container downstream of the short time heating system for receiving the medium, and a rotary filling device downstream of the buffer container. The filling device is connected to the buffer container in a buffer-free manner and pipes and/or one or more rotary distributors are disposed between the filling device and the buffer container. A method for pasteurizing and filling medium into containers, where filling the containers with the medium is performed by way of a device in a buffer-free manner using a filling device, includes: pasteurizing the medium in the short time heating system, buffering the pasteurized medium in the buffer container, and filling the pasteurized medium into the containers. The pasteurized medium is transported in a buffer-free manner from the buffer container to the filling device.