Dynamic F-Value Control for Aseptic Drink Pipeline Sterilization
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Solution Overview
Problem
Conventional SIP treatment for drink supply pipelines in aseptic filling systems is inefficient in terms of energy consumption and productivity, as it relies on a fixed 30-minute heating at 130°C to achieve sterilization, ignoring the integrated F-value contribution from temperatures between 121.1°C and 130°C, and lacks precise temperature control across branched pipe lines.
Innovation Solution
Implement a method where hot water or heated steam is fed to the drink supply pipeline, with temperature sensors at multiple points and nozzles to calculate F-values at predetermined intervals, ending the sterilization process when the minimum F-value reaches the target, allowing for earlier completion of the sterilization process and improved precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed 30-minute heating at 130°C is applied to ensure sterilization, then sterilization reliability is improved, but energy consumption increases and productivity decreases
Solution Approach 1:
The patent transitions from a static fixed-time sterilization method to a dynamic F-value based method. The sterilization process is continuously monitored through temperature sensors at multiple points, and the process duration dynamically adjusts based on the calculated F-value accumulation. This allows the system to terminate sterilization early when the target F-value is reached, improving productivity while maintaining reliability.
Solution Approach 2:
The patent implements a feedback control system where temperature sensors continuously monitor temperatures at multiple points in the pipeline, the controller calculates F-values based on these temperature readings, and the sterilization process is adjusted accordingly. This closed-loop feedback mechanism ensures reliable sterilization by verifying F-value accumulation while avoiding unnecessary extended heating, thus improving productivity.
2Reliability
If fixed 30-minute heating at 130°C is applied to ensure sterilization, then sterilization reliability is improved, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts sterilization duration based on real-time temperature monitoring and F-value calculation. Instead of applying fixed 30-minute heating regardless of actual sterilization needs, the process terminates as soon as the cumulative F-value reaches the target, significantly reducing energy consumption while maintaining sterilization reliability through continuous monitoring.
Solution Approach 2:
The feedback control system continuously monitors temperatures at multiple points and calculates F-value accumulation in real-time. This feedback mechanism prevents unnecessary energy consumption by terminating the heating process early when the sterilization target is achieved, while ensuring reliability through continuous verification of F-value accumulation.
3Device complexity
If temperature sensors are placed only at specific points to simplify measurement, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent divides the sterilization monitoring into multiple segments by placing temperature sensors at several key points throughout the pipeline (including heated sections, non-heated sections, and filling nozzles). This segmentation allows comprehensive temperature monitoring and accurate F-value calculation for different pipeline sections, improving measurement precision without excessive complexity.
Solution Approach 2:
The patent applies local quality monitoring by placing temperature sensors at specific locations where temperature characteristics differ (heated sections, non-heated sections, filling nozzles). Each sensor monitors the local temperature conditions specific to its location, enabling precise F-value calculation for each section and ensuring accurate overall sterilization verification.
4Manufacturing precision
If F-value calculation is performed at multiple points to improve sterilization accuracy, then sterilization precision is improved, but device complexity increases
Solution Approach 1:
The patent segments the F-value calculation into multiple independent calculations based on temperature readings from different sensor locations. Each location's F-value is calculated separately using its local temperature data, and the minimum F-value determines process termination. This segmentation approach improves sterilization precision by accounting for temperature variations throughout the pipeline while keeping the control logic relatively simple.
Solution Approach 2:
The system uses the temperature data collected from multiple sensors to automatically perform F-value calculations and determine process termination without requiring complex external control. The controller autonomously processes the temperature readings, calculates F-values for each section, and makes termination decisions based on the minimum F-value, reducing the need for additional complex control mechanisms.
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 precise and speedy aseptic sterilization of the drink supply pipeline, reducing energy consumption, shortening production time, and improving overall efficiency by calculating F-values across all nozzles and pipeline sections.
Implementation Method 1
hot water or heated steam is fed to a drink supply pipe line (7) for simultaneously supplying drink to a plurality of filling nozzles (2a)
Implementation Method 2
circulating heated steam or hot water through the drink filling path
Data Source
AI summary
Hot water or heated steam is fed to a drink supply pipe line for simultaneously supplying drink to a plurality of filling nozzles, while exhausting the hot water or heated steam from all the filling nozzles, F-values are calculated by detecting temperatures at a plurality of predetermined portions of the drink supply pipe line and all the filling nozzles 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, the sterilization to the drink supply pipe line can be smoothly performed.