Aseptic Drink Filling Pipe Sterilization via Real-Time F-Value Monitoring
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Solution Overview
Problem
Conventional aseptic drink filling systems face inefficiencies in sterilization due to prolonged heating times and high energy consumption during SIP treatments, which affect productivity and energy usage.
Innovation Solution
A method that calculates the F-value by integrating temperature over time, allowing for early termination of the sterilization process when the aimed F-value is reached, using a combination of hot water and heated steam in the drink supply pipe line with upstream and downstream circulation paths, and controlling the sterilization process based on temperature sensors to reduce heating and cooling times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional SIP treatment is performed by circulating steam or heated water for a fixed time (e.g., 30 minutes) to ensure sterilization, then the sterilization reliability is improved, but the production time is increased and productivity is reduced
Solution Approach 1:
The system continuously measures the temperature at multiple locations within the drink supply pipe line and uses this feedback to calculate the F-value in real-time. The sterilization process is dynamically adjusted based on the actual temperature distribution, allowing the process to terminate as soon as the target F-value is achieved at all measurement points, rather than running for a fixed time.
Solution Approach 2:
The sterilization process transitions from a static, fixed-time approach to a dynamic, adaptive process. The heating time and temperature profile are continuously adjusted based on real-time temperature measurements and F-value calculations, optimizing the sterilization process for each specific situation.
2Reliability
If conventional SIP treatment uses fixed heating time and temperature to ensure adequate sterilization, then the sterilization effect is improved, but the energy consumption is increased
Solution Approach 1:
The system uses real-time temperature measurements from multiple sensors to continuously calculate the F-value and monitor the sterilization progress. This feedback mechanism allows the system to stop heating as soon as the target F-value is achieved, preventing unnecessary energy consumption from extended heating periods.
Solution Approach 2:
Instead of applying excessive heating for a fixed duration, the system applies heating dynamically based on the actual sterilization needs. The process uses partial action by stopping heating as soon as the minimum F-value is achieved at all measurement points, avoiding the excessive energy consumption of fixed-time heating.
3Measurement precision
If temperature sensors are placed at multiple portions of the drink supply pipe line to monitor sterilization, then the measurement precision is improved, but the device complexity is increased
Solution Approach 1:
The drink supply pipe line is divided into multiple measurement sections, with temperature sensors placed at representative locations in each section. This segmentation allows the system to monitor temperature distribution throughout the pipe line using a manageable number of sensors, balancing measurement precision with system complexity.
Solution Approach 2:
The system uses an F-value calculation as an intermediary parameter that integrates temperature measurements from multiple sensors over time. This intermediary calculation simplifies the complex task of monitoring sterilization at multiple points by providing a single composite metric that represents the overall sterilization status.
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 enables more accurate and rapid aseptic treatment, reducing the amount of hot water or steam used, allowing for earlier start of drink filling operations and shorter production intervals, thereby enhancing production efficiency.
Implementation Method 1
hot water or heated steam is fed in a drink supply pipe line (7)... temperatures at a plurality of portions of the drink supply pipe line (7)... F-values are calculated
Implementation Method 2
temperatures at a plurality of portions of the drink supply pipe line (7)... are measured by temperature sensors
Implementation Method 3
F-values are calculated while detecting temperatures at a plurality portions of the drink supply pipe line (7) at every predetermined time interval... F-value has been measured so as to confirm whether it is worth while for the drink to receive quality guarantee
Data Source
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AI summary
In a sterilizing method for a drink filling system provided with a drink supply pipe line (7) for feeding drink into a filling machine (2) through a heating sterilizing section (18), wherein hot water or heated steam is fed to the drink supply pipe line (7), F-values are calculated while detecting temperature at a plurality portions of the drink supply pipe line at every predetermined time interval, and a sterilizing process is ended at a time when a minimum F-value reaches an aimed value. According to such method, a working time till the starting of drink filling work or a producing interval time can be shortened.