Closed-Container Pasteurization With Adaptive Thermal Profiles
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Solution Overview
Problem
Existing systems for heating and cooling filled containers in automated processes face challenges in energy consumption and overpasteurization due to temporary stops and changes in transport speed, leading to inefficient energy use and poor process control.
Innovation Solution
A system that controls the transport speed and temperature profile based on predicted system parameters, adjusting the number of pasteurization zones and temperature settings to match anticipated throughput changes, using detection devices to monitor inlet and outlet conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the transport speed is increased, then the productivity is improved, but the temperature treatment becomes insufficient leading to poor pasteurization results
Solution Approach 1:
The patent applies dynamics by making the temperature profile adjustable and adaptive rather than fixed. The control device dynamically modifies temperature settings in different zones based on the actual transport speed, allowing the system to maintain effective pasteurization across varying productivity levels. This resolves the contradiction by enabling the system to adapt its thermal treatment parameters to match the dynamic transport conditions.
Solution Approach 2:
The patent implements parameter changes by modifying temperature profile parameters (temperature levels, zone distributions) in response to transport speed variations. When transport speed increases, the system adjusts temperature parameters to ensure adequate heating time; when speed decreases, it prevents overheating. This dynamic parameter adjustment resolves the contradiction between maintaining high productivity and ensuring reliable pasteurization quality.
2Reliability
If the transport speed is reduced, then the pasteurization quality is improved, but the productivity decreases
Solution Approach 1:
The system uses dynamic control to adjust the temperature profile according to the actual transport speed. When speed is reduced, the control device lowers temperature parameters to prevent overpasteurization while maintaining adequate treatment. This dynamic adaptation allows the system to maintain high pasteurization quality without necessarily reducing productivity, as the temperature parameters are optimized to match the slower transport conditions.
Solution Approach 2:
The patent applies parameter changes by modifying temperature profile settings based on transport speed. At reduced speeds, the system adjusts temperature parameters downward to avoid excessive heating, thereby maintaining pasteurization quality while preventing energy waste and product degradation. This resolves the contradiction by enabling quality maintenance at lower productivity levels when necessary.
3Reliability
If the pasteurizer stops temporarily due to congestion or limited product availability, then the product treatment is maintained, but the temperature of the treatment medium causes overpasteurization when resuming operation
Solution Approach 1:
The patent implements feedback control by continuously monitoring transport speed and using this information to adjust the temperature profile. When the system detects stops or speed variations, the control device receives feedback and modifies temperature parameters accordingly. This feedback mechanism prevents overpasteurization after resumption by ensuring temperature settings match actual transport conditions, thereby reducing energy loss while maintaining treatment consistency.
Solution Approach 2:
The system applies preliminary action by proactively adjusting the temperature profile in anticipation of transport speed changes or stops. The control device modifies temperature parameters before resumption occurs, preventing the treatment medium from overheating during idle periods. This preliminary adjustment avoids the energy waste associated with cooling down overheated medium while ensuring consistent product treatment upon resumption.
4Reliability
If the temperature of the treatment medium is raised to ensure adequate product treatment at full capacity, then the pasteurization quality is improved, but energy consumption increases during temporary stops
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting temperature profile parameters based on actual transport speed and system operation status. Instead of maintaining high temperatures during stops, the control device modifies temperature parameters to match current operational conditions. This resolves the contradiction by enabling high pasteurization quality during active operation while significantly reducing energy consumption during temporary stops or low-speed periods.
Solution Approach 2:
The system uses dynamic control to make the temperature profile adaptive rather than static. The control device continuously adjusts temperature parameters in response to transport speed variations and operational status. This dynamic approach allows the system to maintain high pasteurization quality when needed while automatically reducing energy consumption during stops or low-demand periods, resolving the contradiction between quality and energy use.
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 reduces energy consumption and prevents overpasteurization by optimizing the heating and cooling process based on future system conditions, ensuring consistent product treatment and efficient energy use.
Implementation Method 1
a transport device (4) configured to transport the containers (3) in a transport direction (5)
Implementation Method 2
a device (6) designed for heating and/or cooling the containers (3) according to a temperature profile (7) along the transport direction (5)
Implementation Method 3
a device (6) designed for heating and/or cooling the containers (3) according to a temperature profile (7) along the transport direction (5)
Data Source
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AI summary
The invention relates to a system for heating and/or cooling, in particular pasteurizing, closed containers filled with a liquid, in particular. The system comprises a transport device configured for moving the containers in a transport direction, a device configured for heating and/or cooling the containers according to a temperature profile along the transport direction, and a control device configured for controlling the transport speed of the transport device and the temperature profile. The control device is configured to alternate the transport speed between a stop and a nominal transport speed and to control the temperature profile based on a predicted system parameter.The invention also relates to a method for heating and/or cooling, in particular pasteurizing, containers filled with a liquid and sealed substance using such a system. The method comprises transporting the containers in the transport direction, heating and/or cooling the containers according to the temperature profile along the transport direction, controlling the transport speed of the transport device and the temperature profile, wherein the transport speed alternates between a stop and the nominal transport speed over time, predicting the system parameter, and controlling the temperature profile depending on the predicted system parameter.