Container Filling Nozzle Control to Prevent Drips and Blockages
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Solution Overview
Problem
Conventional filling systems face issues with fluid dynamic behaviors leading to overfilling, underfilling, and blockages in containers, resulting in waste and inconsistent fill volumes, especially with expensive biologic-based drug products, due to drip loss and solid plug formation in the nozzle.
Innovation Solution
A filling system with a processor-controlled pump and nozzle actuator that generates operating parameters to form a stable fluid interface with a stable resting profile in the nozzle, using fluid properties and system parameters to prevent dripping and blockages, by maintaining a controlled Bond number and minimizing film thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional filling systems distribute fluid through nozzles without accounting for fluid dynamic behaviors, then filling throughput is maintained, but filling accuracy deteriorates and blockages occur
Solution Approach 1:
The system dynamically adjusts pump speed and nozzle positioning based on real-time fluid property measurements (viscosity, surface tension, density) to optimize filling parameters. This allows the system to maintain high throughput while achieving consistent fill accuracy by adapting operational parameters to match the specific fluid being processed.
Solution Approach 2:
The system incorporates sensors to monitor fluid properties and filling outcomes, using this feedback to continuously adjust pump speed, nozzle height, and fill volume. This closed-loop control prevents both overfilling and underfilling while maintaining optimal throughput by correcting deviations in real-time.
2Productivity
If pump speed is increased to improve throughput, then productivity increases, but fluid dynamic instability worsens leading to dripping and blockages
Solution Approach 1:
The system uses variable speed pumping rather than fixed speed, allowing the pump to dynamically adjust its operation based on fluid properties and filling requirements. This dynamic control maintains stable fluid flow at high throughput by preventing conditions that lead to dripping and solid plug formation.
Solution Approach 2:
The system performs preliminary measurements of fluid properties (viscosity, surface tension) before initiating the filling process, allowing it to pre-calculate optimal pump speed and flow parameters. This preliminary action prevents fluid dynamic instability before it occurs, ensuring both high throughput and reliable stable flow.
3Manufacturing precision
If nozzle size is reduced to improve filling precision, then manufacturing precision improves, but fluid flow blockage risk increases
Solution Approach 1:
The system adjusts multiple parameters including pump speed, fluid pressure, and nozzle positioning based on measured fluid properties. For small nozzles requiring high precision, the system compensates for increased blockage risk by optimizing flow rate and pressure parameters to prevent solid plug formation while maintaining precise fill control.
Solution Approach 2:
The system replaces purely mechanical nozzle sizing decisions with a controlled fluid delivery system that uses pump speed modulation and real-time fluid property measurement to achieve precision. This substitution allows small nozzles to operate reliably by controlling fluid dynamics rather than relying solely on nozzle dimensions.
4Productivity
If fluid is allowed to remain in the nozzle between fills, then filling speed improves, but fluid drying and contamination worsen
Solution Approach 1:
The system implements periodic flushing cycles where a small amount of fluid is pumped through the nozzle at regular intervals to prevent drying. This periodic action maintains nozzle patency and prevents contamination between fills while minimizing the time the nozzle remains idle, thereby preserving productivity.
Solution Approach 2:
The system maintains continuous fluid movement through the nozzle by implementing a recirculation mode or minimal flow state between fills. This continuous action prevents fluid stagnation and drying while keeping the nozzle ready for immediate filling, eliminating idle time and maintaining high productivity.
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 achieves consistent filling accuracy, reduces downtime, and minimizes material waste by preventing fluid loss and nozzle clogging, ensuring precise distribution of pharmaceutical liquids in delivery devices.
Implementation Method 1
a pump fluidly coupled to the reservoir and at least one filling nozzle configured to distribute the filling fluid through the filling nozzle and the nozzle opening
Implementation Method 2
a stable fluid interface with a stable resting profile forms in the filling fluid in the filling nozzle adjacent to the nozzle opening
Implementation Method 3
a stable fluid interface with a stable resting profile forms in the filling fluid in the filling nozzle adjacent to the nozzle opening
Data Source
AI summary
Systems and methods for distributing a filling fluid are discussed. More particularly an exemplary filling system may include a reservoir holding a filling fluid for distribution. The filling system may also include a pump and filling nozzle fluidly coupled to the reservoir. A processor executes a filling module that when executed receives at least one input fluid property of the filling fluid and generates at least one set of operating parameters for controlling operation of the pump during a filling operation based at least in part on the fluid property. The generated set of operating parameters enable control of the pump to distribute the filling fluid through the filling nozzle, such that a fluid interface with a stable resting profile forms in the filling fluid in the filling nozzle adjacent to the nozzle opening after the filling fluid is distributed from the filling nozzle.