Container Airlock Isolator Recirculation for Sterile Atmosphere
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Solution Overview
Problem
Existing container treatment systems in beverage bottling plants face inefficiencies in air treatment and microbiological safety, particularly in maintaining a sterile atmosphere within isolator rooms, leading to potential condensation and microbial growth issues.
Innovation Solution
A device and method that recirculate and re-treat air extracted from the isolator room and container locks, using a variable volume flow divider to optimize air processing, combined with ambient and fresh air supplies, and cold traps to remove disinfectants, enhancing sterility and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ambient air is continuously supplied to the isolator room through a central supply air treatment system, then the defined atmosphere (low germ load, controlled temperature and humidity) is maintained, but energy consumption increases due to continuous processing of fresh air
Solution Approach 1:
The patent implements a recirculation system where a portion of the air extracted from the isolator room is returned to the supply air treatment system for continuous re-processing. This maintains the defined atmosphere continuously without requiring 100% fresh air supply, thereby reducing energy consumption while preserving microbiological safety through repeated filtration and treatment cycles
Solution Approach 2:
The system recovers and reuses a portion of the air extracted from the isolator room by feeding it back to the supply air treatment system. Instead of discarding all extracted air, the recirculation concept allows the already partially treated air to undergo further processing, reducing the need for continuous fresh air generation and lowering overall energy consumption
2Ease of operation
If the air extracted from the container lock is discharged to the outside, then the negative pressure and air flow control are simplified, but microbiological safety is compromised as treated air is wasted
Solution Approach 1:
The patent establishes a continuous recirculation loop where air extracted from the container lock is fed to the supply air treatment system rather than being discharged. This creates an ongoing process of treatment and reuse, maintaining microbiological safety by ensuring that air entering the isolator room has undergone multiple treatment cycles, while still allowing operational simplicity through automated control
3Reliability
If extensive temperature and humidity adjustments are made to maintain the defined atmosphere, then the isolator room conditions are optimized, but energy consumption increases
Solution Approach 1:
The recirculation system enables continuous conditioning of air that has already been partially processed. By repeatedly passing air through the supply air treatment system, the temperature and humidity can be gradually adjusted to the desired setpoints with less energy input compared to continuous fresh air conditioning, while maintaining optimized isolator room conditions
Solution Approach 2:
The system utilizes gradual parameter changes through multiple recirculation cycles. Instead of making extensive single-pass adjustments, the air undergoes incremental temperature and humidity modifications with each pass through the treatment system, reducing the overall energy required for atmosphere control while achieving the same final conditions
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 improves microbiological safety and efficiency by re-filtering and re-conditioning air, reducing the need for extensive temperature and humidity adjustments, and minimizing energy use while maintaining a sterile atmosphere within the isolator room.
Implementation Method 1
a suction device for sucking air out of the container lock and from the isolator room
Implementation Method 2
the air is cleaned, for example, using filter systems
Implementation Method 3
brought to a specified humidity level using appropriate dehumidifiers or humidifiers
Implementation Method 4
brought to a specified temperature using appropriate temperature control means
Implementation Method 5
a variable volume flow divider downstream of the suction device, by means of which a proportion of the extracted air volume can be fed to the supply air treatment
Implementation Method 6
a cold trap downstream of the suction device in order to free the air sucked out of the container lock and isolator room from disinfectant
Implementation Method 7
a catalytic converter instead of or in addition to the cold trap, by means of which the disinfectant can be broken down
Data Source
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AI summary
The present invention relates to a device (1) for treating at least one container, preferably for filling at least one container with a filling product and/or for reshaping a container, comprising an isolator chamber (2) containing a defined atmosphere in which the treatment of the container is carried out, and at least one container airlock (30, 32) for introducing the container into the isolator chamber (2) or for removing the container from the isolator chamber (2), furthermore an extraction device (4) for extracting air from the container airlock (30, 32) and from the isolator chamber (2), and an air supply system (5) for conditioning the air supplied to the isolator chamber (2), wherein the extraction device (4) is connected to the air supply system (5) in such a way that at least a portion of the air extracted from the container airlock (30, 32) and/or the isolator chamber (2) is supplied to the air supply system (5) for reconditioning. becomes.