Container Filling Pressure Control for Thermal Stress Reduction
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Solution Overview
Problem
Existing container filling and closing methods expose containers to hot flushing gas for extended periods, leading to excessive temperature stress and increased breakage, particularly in glass containers, which reduces productivity and causes interruptions in container handling machines.
Innovation Solution
A method utilizing a pressure sensor-controlled process chamber that evacuates containers to a negative pressure, flushes them with steam to atmospheric pressure, and adjusts pressure conditions for filling and closing, minimizing steam treatment time and energy input, thereby reducing thermal stress on containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If containers are flushed with hot steam for extended periods to ensure aseptic conditions, then sterilization effectiveness is improved, but thermal stress on containers increases leading to breakage
Solution Approach 1:
The container is evacuated to negative pressure before steam flushing begins. This preliminary action creates a pressure differential that accelerates steam condensation and reduces the time the container is exposed to high-temperature steam, thereby maintaining sterilization effectiveness while reducing thermal stress exposure duration
Solution Approach 2:
The process uses periodic pressure changes - first evacuating to negative pressure, then flushing with steam at atmospheric pressure, and finally adjusting to positive pressure. These periodic pressure variations control steam behavior and condensation rate, optimizing both sterilization and thermal stress reduction
2Productivity
If containers are evacuated to negative pressure and flushed with steam rapidly, then processing time is reduced, but pressure control complexity increases
Solution Approach 1:
A pressure sensor continuously monitors the pressure inside the process chamber and provides feedback to the control system. This feedback mechanism enables automatic adjustment of vacuum pump and steam valve operations, achieving rapid and safe pressure transitions without requiring complex manual control systems
Solution Approach 2:
The pressure sensor and control system work together to automatically regulate the pressure conditions throughout the process. The system self-adjusts based on real-time pressure readings, eliminating the need for complex external control mechanisms while maintaining precise pressure management
3Reliability
If steam flushing is performed at atmospheric pressure for extended periods, then aseptic conditions are maintained, but energy consumption increases
Solution Approach 1:
Evacuating the container to negative pressure before steam flushing creates conditions where steam condenses more rapidly upon contact with the cold liquid and container surfaces. This preliminary evacuation reduces the total time steam must be supplied, thereby reducing energy consumption while maintaining aseptic conditions
Solution Approach 2:
The process alternates between vacuum phases and steam flushing phases, with pressure adjustments occurring periodically. This periodic action ensures aseptic conditions are maintained during critical phases while minimizing steam exposure time during less critical phases, optimizing energy efficiency
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 significantly reduces container breakage and processing time, enhancing productivity by minimizing thermal stress and optimizing handling efficiency while maintaining aseptic conditions for filling beverages.
Implementation Method 1
with at least one pressure sensor DS for detecting the actual pressure values prevailing in the process chamber 17
Implementation Method 2
in an evacuation phase, initially at least once to a negative pressure or a pressure below atmospheric pressure
Implementation Method 3
a sudden condensation occurs of at least a part volume of the steam or vapor present in the container
Implementation Method 4
in a flushing phase, is flushed with steam and/or with a flushing gas containing steam
Data Source
AI summary
In a method of filling and closing containers, such as bottles and similar containers, for containing liquid products, such as beverages and similar products, the filling and closing can be performed in a filling and closing machine or arrangement.