On-Site Chlorine Dioxide Mixing System for Dairy Hygiene

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Solution Overview

Problem

Current chlorine dioxide-based teat dip solutions for dairy farms face challenges due to the need for on-site mixing, high costs, and short shelf life, which limits their adoption and effectiveness in preventing mastitis, a costly disease in the dairy industry.

Innovation Solution

An on-site system for producing ready-to-use chlorine dioxide sanitizing solutions using a combination of precursor source vessels, an activation chamber, and measurement/mixing vessels, which increases concentration levels, reduces chemical usage, and enhances mixing accuracy and safety, allowing for specific formulation creation tailored to pre-milking and post-milking applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If chlorine dioxide-based teat dip solutions are produced using conventional on-site mixing methods, then the solutions can be prepared at the dairy farm, but the mixing accuracy is poor and chemical usage is inefficient

Engineering Contradiction:

Improvemixing accuracyVSAvoidchemical usage efficiency

Core Design Contradiction:

Measurement precisionVSQuantity of substance

Solution Approach 1:

The patent replaces manual or simple mechanical mixing methods with an automated electronic control system that uses sensors, pumps, and a microprocessor to precisely measure and mix chemical precursors. This substitution of mechanical mixing with an automated control system achieves accurate mixing ratios while minimizing chemical waste through precise dosage control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Duration of action of stationary object

If concentrated chlorine dioxide solutions are stored and transported, then distribution is simplified, but the shelf life is short and handling costs increase

Engineering Contradiction:

Improveshelf lifeVSAvoidhandling and storage expenses

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The patent divides the chlorine dioxide solution into two stable precursor components that can be stored separately for extended periods. These precursors are mixed in controlled amounts at the point of use, avoiding the need to store and handle unstable concentrated chlorine dioxide solutions. This segmentation extends shelf life of stored components while reducing handling and storage expenses for the active germicidal agent.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent prepares stable precursor solutions in advance that can be stored for long periods. When needed, these precursors are quickly mixed to generate the active chlorine dioxide solution on-site. This preliminary preparation of stable precursors extends shelf life while minimizing the need for expensive specialized handling and storage infrastructure for the active disinfectant.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If high concentrations of germicidal agents are used in post-milking solutions, then prophylactic protection is enhanced, but the cost of chemicals and packaging increases

Engineering Contradiction:

Improveprophylactic protection effectivenessVSAvoidchemical cost and packaging expense

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent uses an automated electronic control system with sensors and proportional pumps to precisely dose the precursor chemicals, ensuring consistent high concentration of active germicidal agent in the final solution without wasting chemicals. This automated dosing maintains reliable prophylactic protection while minimizing chemical costs and packaging requirements compared to manual mixing methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system reduces production costs, minimizes chemical waste, and extends the shelf life of chlorine dioxide solutions, making them more effective and efficient for dairy farm hygiene practices while reducing handling and storage expenses.

Implementation Method 1

an activation chamber for receiving and mixing the precursor solutions to generate chlorine dioxide

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

The on-site system comprises a first peristaltic pump for measuring a first precursor solution into the activation chamber and a second peristaltic pump for measuring a second precursor solution into the activation chamber

Methodology Applied

Scientific EffectPeristalsis: Peristalsis

Data Source

PatentUS12016337B1System for mixing germicidally active solutions, on-site, for dairy/agricultural hygiene purposes

Publication Date: 2024.06.25 ACEPTEC LTD

AI summary

A system for on-site production of chlorine dioxide and other sanitizing solutions is disclosed which includes an activation chamber to mix concentrated activator and base solutions. The resulting solution from the activation chamber is then mixed with water in a two-stage measurement/mixing vessel to create a ready-to-use cleaning solution. A drainage system is employed to transfer the ready-to-use cleaning solution into a reservoir for on-site use.