Monitoring and control of thermal sanitization in automated cleaning machines

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing automated cleaning machines struggle to achieve consistent thermal sanitization of articles independent of ware type, material, and quantity due to variations in temperature profiles and process parameters.

Innovation Solution

Monitoring and controlling cleaning process parameters based on the sump temperature difference at the beginning of the cleaning process to adjust wash time, rinse time, and rinse temperature, ensuring thermal sanitization is achieved by predicting and adjusting Heat Unit Equivalents (HUEs) to meet the NSF 3-2017 standard.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If default cleaning process parameters are used, then the cleaning process can be executed efficiently, but thermal sanitization may not be achieved consistently due to temperature variations

Engineering Contradiction:

Improvethermal sanitization consistencyVSAvoidprocess monitoring and control system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system continuously monitors sump temperature during the cleaning process and uses this feedback to dynamically adjust cleaning parameters. Temperature sensors provide real-time data to the controller, which then modifies wash time, rinse time, or rinse temperature to ensure thermal sanitization targets are met, resolving the contradiction between reliability and complexity by implementing targeted feedback control.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system predicts the number of Heat Unit Equivalents (HUEs) that will be delivered during the cleaning process based on initial sump temperature measurements. This preliminary prediction allows the system to proactively adjust parameters before the cleaning cycle completes, ensuring thermal sanitization is achieved without requiring complex real-time adjustments throughout the entire process.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If cleaning process parameters are adjusted to achieve thermal sanitization, then sanitization reliability improves, but process time and energy consumption increase

Engineering Contradiction:

Improvethermal sanitization achievementVSAvoidcleaning cycle efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system adjusts cleaning parameters only to the extent necessary to achieve thermal sanitization targets. Rather than applying excessive heat or time in all cases, the controller makes precise, minimal adjustments to wash time, rinse time, or rinse temperature based on actual sump temperature measurements, ensuring sanitization reliability while minimizing impacts on productivity.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system dynamically adjusts cleaning process parameters based on real-time sump temperature conditions. Rather than using fixed, conservative parameters that would increase cycle time and energy consumption, the controller adapts parameters such as rinse temperature and timing to match actual thermal conditions, maintaining sanitization reliability while optimizing cleaning cycle efficiency.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If sump temperature is monitored and used to predict HUEs, then cleaning parameter accuracy improves, but measurement and prediction complexity increases

Engineering Contradiction:

Improvecleaning parameter accuracyVSAvoidtemperature monitoring and HUE prediction

Core Design Contradiction:

Manufacturing precisionVSDifficulty of detecting and measuring

Solution Approach 1:

The system uses sump temperature as an intermediary measurement that correlates with the thermal energy delivered to articles. Rather than directly measuring complex parameters like article surface temperature or HUE delivery, the system monitors the easily accessible sump temperature and uses this as a proxy to predict HUEs and adjust cleaning parameters, improving accuracy without excessive measurement complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Ensures thermal sanitization of articles by dynamically adjusting cleaning process parameters, achieving the required HUEs independently of ware type and quantity, enhancing efficiency and cost-effectiveness.

Implementation Method 1

determine a sump temperature difference between a first temperature and a second temperature; predict a number of heat unit equivalents (HUEs) that will be delivered during the cleaning process based on the sump temperature difference

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Data Source

PatentUS12465190B2Monitoring and control of thermal sanitization in automated cleaning machines

Publication Date: 2025.11.11 ECOLAB USA INC

AI summary

Systems and/or methods for the monitoring and/or control of thermal sanitization in automated cleaning machines are described. A cleaning machine controller may predict a number of heat unit equivalents that will be delivered during a cleaning process based on a sump temperature difference (i.e., a change in the temperature of the cleaning solution in the sump) experienced at or near the beginning of the cleaning process. One or more cleaning process parameters may be adjusted and/or controlled based on the sump temperature difference in order to ensure that a target number of heat unit equivalents are delivered in order to achieve thermal sanitization of the wares subjected to the cleaning process.