Continuous Liquid Sterilizer Flow Control for Aseptic Filling
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Solution Overview
Problem
Existing methods for sterilizing liquid supply piping in aseptic filling machines are time-consuming, particularly when transitioning between different liquids, due to the need for extensive CIP and SIP processes, which prolong the preparation time before filling.
Innovation Solution
A method for a continuous liquid sterilizing apparatus that involves sterilizing a first liquid, cleaning the apparatus with a cleaning liquid at a higher flow rate to maintain an F value, and then replacing it with a second liquid at a lower flow rate without performing a separate SIP process, by adjusting temperature and flow rate to ensure effective sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If CIP and SIP processes are performed separately and sequentially for liquid supply piping, then sterilization reliability is improved, but preparation time before filling increases
Solution Approach 1:
The patent combines the CIP process and SIP process into a single integrated operation by introducing a cleaning liquid that simultaneously provides both cleaning and sterilization functions. The cleaning liquid contains a surfactant for cleaning and a sterilizing agent (such as peracetic acid or hydrogen peroxide) that enables sterilization without requiring a separate SIP process, thereby reducing preparation time while maintaining sterilization reliability.
Solution Approach 2:
The cleaning liquid is designed to perform multiple functions: it cleans the liquid supply piping through surfactant action, sterilizes through incorporated sterilizing agents, and rinses without requiring additional water flushing steps. This multi-functional cleaning liquid eliminates the need for separate CIP and SIP processes while ensuring both cleaning and sterilization requirements are met.
2Manufacturing precision
If CIP process duration is extended to ensure thorough cleaning, then cleaning quality is improved, but productivity decreases
Solution Approach 1:
The patent changes the chemical parameters of the cleaning liquid by incorporating sterilizing agents such as peracetic acid or hydrogen peroxide at specific concentrations (e.g., 0.1-10% peracetic acid). These parameter changes enable the cleaning liquid to achieve both cleaning and sterilization in a single process step, reducing the required process duration while maintaining high cleaning quality and eliminating the need for extended CIP processes.
3Reliability
If separate CIP and SIP processes are used for liquid replacement, then aseptic conditions are ensured, but machine availability decreases
Solution Approach 1:
The patent enables continuous operation during liquid replacement by using a cleaning liquid that maintains aseptic conditions throughout the replacement process. The sterilizing agents in the cleaning liquid ensure that the liquid supply piping remains sterile during the transition between different liquids, eliminating downtime between CIP and SIP processes and maintaining continuous productive operation.
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 the preparation time for liquid changes by minimizing the duration of the CIP process and maintaining aseptic conditions, thereby enhancing the availability and productivity of the aseptic filling machine.
Implementation Method 1
a continuous liquid sterilizing apparatus that allows a liquid to flow therethrough and sterilizes the liquid by heating the liquid from outside
Implementation Method 2
the inside of the continuous liquid sterilizing apparatus is cleaned by flowing a cleaning liquid at a flow rate higher than a flow rate of the first liquid
Data Source
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AI summary
To provide a liquid replacement method for a continuous liquid sterilizing apparatus that can improve the availability of an aseptic filling machine and allow efficient production of liquid-filled products. In a liquid replacement method for a continuous liquid sterilizing apparatus that allows a liquid to flow therethrough and sterilizes the liquid by heating the liquid from outside, a first liquid is sterilized by the continuous liquid sterilizing apparatus, an inside of the continuous liquid sterilizing apparatus is cleaned by flowing a cleaning liquid at a flow rate higher than a flow rate of the first liquid while sterilizing the cleaning liquid by the continuous liquid sterilizing apparatus in such a manner that an F value does not become lower than a target F value, and a second liquid is flowed at a flow rate lower than the flow rate of the cleaning liquid while being sterilized by the continuous liquid sterilizing apparatus in such a manner that the F value does not become lower than the target F value.