Dual-Path Filling Valve for Free-Jet and Wall Filling
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Solution Overview
Problem
Current filling systems for beverage bottling plants are limited in their ability to efficiently handle both free-jet and wall filling processes for non-carbonated and carbonated products, as they require separate systems, leading to suboptimal filling speeds and aseptic filling challenges.
Innovation Solution
A filling element with dual product paths, one for free-jet filling and another for wall filling, integrated into a single device, allowing for optimal geometry and flow optimization in each mode without compromising quality, using a movable valve cone and gas channels for pressurization and pressure relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate filling systems are used for free-jet and wall filling, then each process can be optimized for its specific product type, but the device complexity and space requirements increase
Solution Approach 1:
The patent combines two separate filling systems (free-jet filling and wall filling) into a single integrated filling valve. The valve body houses both a valve cone for free-jet filling and a swirl element for wall filling, allowing both filling methods to be performed with one device while maintaining their respective optimizations.
Solution Approach 2:
The filling valve is designed as a multi-functional device that can perform both free-jet filling (using the valve cone) and wall filling (using the swirl element). This universal design allows a single device to handle different product types (carbonated and non-carbonated) with their respective optimal filling methods.
2Device complexity
If a single filling valve is used for both free-jet and wall filling, then device complexity is reduced, but the manufacturing precision and flow optimization for each process suffer
Solution Approach 1:
The filling valve is segmented into distinct functional zones: the valve cone with its specific outlet contour for free-jet filling, and the swirl element with its separate outlet contour for wall filling. Each component is independently designed and manufactured to achieve the precise flow characteristics required for its specific filling method, avoiding compromise in manufacturing precision.
Solution Approach 2:
Different parts of the filling valve have specialized geometries optimized for their specific functions. The valve cone features a narrow, laminar flow outlet contour suitable for free-jet filling, while the swirl element has a rotating, widening outlet contour optimized for wall filling. Each local region of the device has the quality and geometry appropriate for its intended purpose.
3Productivity
If wall filling is used for carbonated products, then filling speed increases, but the requirement for gas-tight connection and pressurization adds operational complexity
Solution Approach 1:
The filling valve integrates the pressurization function directly into the wall filling mechanism. The swirl element includes a bore and valve stem that work together with the gas channel to provide counter-pressure during filling, combining the filling and pressurization operations into a single integrated process.
Solution Approach 2:
The valve stem acts as an intermediary component that performs multiple functions: it controls the opening and closing of the swirl element, regulates the gas flow through the bore for pressurization, and facilitates the gas-tight connection between the container and filling valve. This intermediary element simplifies the overall operation by coordinating multiple functions in one component.
4Reliability
If free-jet filling is used for non-carbonated products, then aseptic filling is achieved, but the filling speed is reduced compared to wall filling
Solution Approach 1:
The filling valve is designed as a universal device that can perform both free-jet filling (for aseptic filling of non-carbonated products) and wall filling (for high-speed carbonated product filling). By integrating both filling methods in one valve, the system can select the appropriate method based on product type, thereby achieving both aseptic capability and high filling speed as needed.
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
Enables efficient and flexible filling of both non-carbonated and carbonated products, reducing the need for multiple systems, improving filling speed, and allowing for aseptic filling, while minimizing resource and cost requirements.
Implementation Method 1
the opening/closing of the valve is achieved via a valve cone at the filling valve outlet. To start the filling process, the valve cone is lifted, and the product flows through the annular gap created
Implementation Method 2
Instead of a valve cone, as in the case of free-jet filling, a swirl element performs the function of opening and closing the valve, and also sets the flowing liquid into rotation. The centrifugal forces of the rotation drive the liquid outwards, causing it to flow along the inner wall of the container
Implementation Method 3
For the same reason, the container is pressurized using the so-called counter-pressure method to ensure the CO2 remains bound in the liquid phase. For this purpose, the container is pressed gas-tight against the filling valve and pre-pressurized with a pressurizing gas, such as CO2, before filling begins
Data Source
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AI summary
Filling element (10) and device for filling a container with a filling product, preferably in a beverage filling plant, wherein the filling element (10) comprises: a first product path (W1) with a first product connection (31) for connection to a first product supply line (131), a first product outlet (53a) for introducing the filling product into the container and a first product line (34) that brings the first product connection (31) and the first product outlet (53a) into fluid communication; a second product path (W2) with a second product connection (32) for connection to a second product supply line (132), a second product outlet (53b) for introducing the filling product into the container and a second product line (35) that brings the second product connection (32) and the second product outlet (53b) into fluid communication;wherein the first product path (W1) is set up to introduce the filling product into the container via the first product outlet (53a) in a first filling product jet, and the second product path (W2) is set up to introduce the filling product into the container via the second product outlet (53b) in a second filling product jet which differs from the first filling product jet.