F Value Calculation for Product Filling Apparatus Sterilization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for cleaning and sterilizing product filling apparatuses, including product supply piping, are time-consuming and inefficient, particularly in transitioning between processes like CIP, SIP, and product sterilization, leading to prolonged preparation times and increased energy consumption.
Innovation Solution
A sterilization process transition method that calculates the F value in real-time using temperature and flowrate data from multiple sensors, allowing for rapid adjustment of temperature and flowrate settings to maintain aseptic conditions, thereby reducing transition time and energy usage by integrating the F value calculation and adjusting the sterilization process dynamically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the CIP process and SIP process are performed in sequence with traditional methods, then the product supply piping is properly cleaned and sterilized, but the transition time between processes is prolonged and energy consumption increases
Solution Approach 1:
The patent implements real-time F value calculation based on temperature and flowrate data from multiple sensors positioned at different locations in the product supply piping. The control unit continuously monitors these parameters and calculates the cumulative sterilization effect (F value) to determine when sterilization is complete, enabling precise process control and reducing unnecessary waiting time while ensuring proper sterilization
Solution Approach 2:
The patent dynamically adjusts temperature and flowrate settings during the transition from CIP to SIP process based on real-time F value calculations. The system can modify process parameters on-the-fly to optimize sterilization efficiency, allowing faster transitions while maintaining sterilization quality requirements
2Reliability
If the temperature and flowrate are adjusted slowly to maintain aseptic conditions during process transition, then sterilization reliability is maintained, but the transition time increases
Solution Approach 1:
The control unit uses real-time feedback from temperature and flowrate sensors to calculate F values and determine the actual sterilization status. This allows the system to make informed decisions about process transitions, maintaining aseptic conditions only when necessary and enabling faster transitions when sterilization targets are achieved
Solution Approach 2:
The system performs preliminary F value calculations during the CIP process to predict when sterilization conditions will be sufficient for transition to SIP. This allows proactive preparation for process transition, reducing downtime while ensuring aseptic conditions are properly established
3Measurement precision
If multiple temperature sensors and flowmeters are installed at arbitrary positions to calculate F value accurately, then sterilization monitoring precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the product supply piping into multiple measurement sections with sensors positioned at strategic locations. The control unit calculates F values for each section independently and determines the minimum F value across all sections, providing comprehensive sterilization monitoring without requiring excessive sensors throughout the entire system
Solution Approach 2:
The control unit performs multiple functions: it monitors temperature and flowrate, calculates F values for different pipe sections, determines sterilization completion, and controls process transitions. This multi-functionality reduces the need for separate dedicated devices for each task, managing system complexity while maintaining measurement precision
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 quicker transitions between sterilization processes, reduces production downtime, conserves water, and enhances operational efficiency by ensuring proper sterilization while minimizing energy consumption.
Implementation Method 1
a heating sterilization part that heats and sterilizes the product
Implementation Method 2
passing a cleaner containing water and an alkali agent such as caustic soda as an additive through a flow path from the pipe line of the product supply piping to the filing nozzles
Implementation Method 3
passing a heated steam or hot water through the product supply piping cleaned by the CIP process
Implementation Method 4
passing a heated steam or hot water through the product supply piping
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Method of cleaning and sterilizing a product filling apparatus that includes product supply piping (7) that feeds a product into a filling machine (2) through a heating sterilization part (18), the method comprising: a CIP process and an SIP process; wherein the CIP process and the SIP process are performed in sequence with-out an interruption between the CIP process and the SIP process; a first manufacturing step of performing a filling step of filling a container with the product while performing a product sterilization process after the SIP process; and a second manufacturing step including the CIP process and the SIP process for manufacturing a product different from that manufactured in the first manufacturing step; the first manufacturing step and the second manufacturing step being performed without reducing the temperature of the heating sterilization part to be equal to or lower than a set temperature of the CIP process.