Closure Sterilization Rotor with Stationary Receptacles
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Solution Overview
Problem
Existing closure sterilization devices face challenges in achieving high sterilization quality and throughput due to the size of the equipment, reliance on rotor movement, and dimensional instability of closures during heating, leading to potential machine malfunctions.
Innovation Solution
A compact device with a single rotor and stationary closure receptacles, utilizing multiple application stations for targeted hydrogen peroxide aerosol application and subsequent drying with heated air, ensuring thorough exposure and maintaining dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If closures are moved through treatment zones by rotor rotation and gravity feeding, then throughput is achieved, but treatment time depends on falling speed and sterilization quality is compromised
Solution Approach 1:
The rotor rotates to present different closure groups to stationary treatment zones at controlled intervals, dynamically adjusting which closures receive which treatment without requiring individual closure movement control. This maintains throughput while ensuring consistent treatment time exposure.
Solution Approach 2:
The system uses periodic rotor rotation to cycle closures through different treatment zones (sterilization, activation, drying) in sequence. Each rotor position corresponds to a specific treatment phase, ensuring that closures receive the full treatment cycle with adequate time in each zone while maintaining continuous operation.
2Productivity
If closures are preheated to 50-85°C for effective sterilization, then sterilization rate is improved, but closures lose dimensional stability and become soft
Solution Approach 1:
Closures are preheated in a dedicated first treatment zone before the sterilization zone. This preliminary heating action prepares the closures for subsequent sterilization by activating the hydrogen peroxide and removing moisture, ensuring effective sterilization while controlling the thermal exposure time to prevent excessive softening.
Solution Approach 2:
The heating and sterilization process is divided into separate treatment zones: a first zone for preheating and moisture removal, and a second zone for sterilization with hydrogen peroxide. This segmentation allows optimized temperature and time parameters for each stage, achieving high sterilization rates while limiting total thermal exposure to maintain dimensional stability.
3Reliability
If two rotors are used for sterilization treatment, then sterilization effectiveness is improved, but device size becomes considerable
Solution Approach 1:
A single rotor performs multiple functions by cycling closure groups through different stationary treatment zones during rotation. The same rotor accomplishes what previously required two separate rotors: preheating in the first zone, sterilization in the second zone, and drying in the third zone. This multi-functional approach maintains sterilization effectiveness while reducing device size.
Solution Approach 2:
Multiple treatment functions (preheating, sterilization, drying) that previously required separate rotor systems are merged into a single integrated rotor system with stationary treatment zones. The rotor acts as a universal carrier that sequentially presents closures to different treatment environments, combining multiple processes into one compact unit.
4Productivity
If closures are moved freely during transport and treatment, then throughput is maintained, but machine malfunctions occur due to dimensional instability
Solution Approach 1:
Closures are extracted from free movement and held in fixed positions within closure receptacles during treatment. The receptacles provide stable containment that prevents closures from shifting or becoming dislodged, even when closures become soft from heating. This extraction of closures from uncontrolled movement eliminates machine malfunctions while maintaining continuous throughput through rotor rotation.
Solution Approach 2:
Closure receptacles serve as intermediary structures between the rotor and closures. These receptacles provide stable, fixed positions for closures during treatment, acting as a mediator that prevents direct contact and potential malfunction between soft, dimensional-unstable closures and the machine components. The receptacles maintain throughput by allowing organized, controlled movement of contained closure groups.
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 design achieves high sterilization rates with a compact and efficient process, maintaining closure stability and enabling trouble-free operation, thereby enhancing the sterilization quality and throughput.
Implementation Method 1
spray devices (20, 20') directed at least one closure receptacle (11) for the controlled and/or targeted application of hydrogen peroxide aerosol/vapour, a hydrogen peroxide aerosol
Implementation Method 2
a gas to activate the hydrogen peroxide and dry the surfaces
Data Source
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AI summary
Device and method for the sterilization of seals (2) for closing bottles or similar containers, in particular for the sterilization of cap-like seals, with a transport system for moving the seals (2) through at least one treatment zone in which the seals (2) are sterilized, wherein the transport system in the at least one treatment zone has at least one rotor (10), which can be driven in rotation about a machine or rotor axis (MA), with a multiplicity of seal holders (11) formed on the periphery of this rotor (10), with which seal holders the seals (2) can be moved through the at least one treatment zone along a treatment path between a seal input (31) and a seal output (33). On the at least one treatment path, there is at least one application station (23, 24) with a spraying device (20, 20') for sterilizing agent, which spraying device (20, 20') is directed towards at least one seal holder (11), in order to apply a sterilizing agent to the individual seals (2) held in the seal holder (11).