Carousel Filling Machine Reducing Foam With Centrifugal Force
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Solution Overview
Problem
Existing container filling machines are bulky, costly to maintain, and suffer from significant product loss due to foam formation during high-speed filling operations, which is not effectively addressed by current solutions.
Innovation Solution
A carousel-type machine that rotates bottles during filling, using centrifugal force to reduce foam formation by entrapping carbon dioxide and directing the product flow along the lateral walls, while also integrating labeling capabilities to reduce overall plant size and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate processing stations (filling machine, labelling machine) are used, then each function can be optimized independently, but the overall plant becomes bulky and maintenance costs increase
Solution Approach 1:
The patent combines the filling machine and labelling machine into a single integrated device mounted on the same carousel. The filling device includes a filling head that can fill containers while the labelling device applies labels to the same containers during their rotation on the carousel, eliminating the need for separate processing stations and reducing overall plant complexity.
Solution Approach 2:
The carousel structure serves multiple functions simultaneously: it transports containers, positions them for filling, and positions them for labelling. The single carousel system performs what previously required multiple separate machines, making the system more versatile and reducing the number of components that require maintenance.
2Productivity
If high-speed filling is used to increase productivity, then filling speed improves, but foam formation increases causing product loss
Solution Approach 1:
The patent introduces a dwell station positioned before the filling station where containers are temporarily held in a stationary position. This allows the filling operation to occur at a controlled speed with the container stable, preventing foam formation while maintaining high overall productivity. The container remains on the carousel but at a fixed angular position during filling.
Solution Approach 2:
The patent changes the operational parameters of the filling process by introducing variable speed control for the carousel. The carousel can operate at different speeds depending on the station: slower at the filling station to prevent foam, and faster during transport between stations to maintain productivity. This dynamic parameter adjustment resolves the contradiction between speed and foam formation.
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
Significantly reduces foam formation and product loss during filling, enhances filling speed, and decreases operational and maintenance costs by integrating filling and labeling processes on a single machine.
Implementation Method 1
A carousel-type machine that rotates bottles during filling, using centrifugal force to reduce foam formation by entrapping carbon dioxide and directing the product flow along the lateral walls
Implementation Method 2
using centrifugal force to reduce foam formation by entrapping carbon dioxide
Data Source
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AI summary
A machine (1) for filling containers (2) comprising: - a conveying device (5); - at least one handling unit (12) fed by the conveying device (6) along a path (P) and comprising support means (13) for receiving and retaining a container (2), and at least one filling device (14) for feeding a pourable product into the container (2) as the handling unit (12) travels along the path (P); and - labelling means (40) configured to feed a label (41) to the handling unit (12) while the handling unit (12) is advanced along the path (P) by the conveying device (5).